6 Nov 06
5
CIP (Cleaning In Place) Systems
A CIP system consists of equipment, pipework 1. Time: Up to an hour depending on the quantity
and concentration of cleaning solution applied.
and automation systems that manage the
circulation of cleaning and sanitation materials
2. Temperature: Cleaning effectiveness is highly
through the targeted food equipment and
dependent on temperature selection. Extreme
pipework. CIP systems that are correctly
temperatures may cook / bake soil on, making
designed and operated enable food processing
it very difficult to remove. Low temperatures
equipment and pipework to be consistently
may reduce cleaning efficiency so that soil is
cleaned and sanitised to the desired standard
not completely removed. The CIP system
without costly dismantling or reassembly of
should monitor and maintain the solution
equipment.
temperature at all parts of the system
throughout the cleaning cycle, and prevent
Advantages and disadvantages
production if the system has not been
adequately cleaned.
The advantages of using CIP systems include; cost
and reliability gains from reduced manual work and
3. Concentration (cleaning chemicals and
the reduced risk of accidental recontamination from
sanitisers): Concentrations (i.e. the strength) of
the need to reassemble equipment after it has been
the cleaning/sanitising chemicals must be
cleaned and sanitised. To gain these types of
maintained within set ranges. The system
advantages, the three main factors given below
should prevent production if concentrations
should be carefully considered, otherwise
were not maintained within the acceptable
disadvantages such as increased costs and
range. Too lower concentrations or too higher
complexity may arise.
concentrations of cleaning/sanitising chemicals
will not clean and sanitise the plant effectively.
1. A correctly designed CIP system: This ensures
that the plant is clean. It also prevents issues
4. Mechanical force: To achieve adequate
such as risk of chemicals contaminating the
cleaning, the equipment or pipework surfaces
product side, excessive waste/cost from poor
must be contacted with cleaning liquid with
valve selection/sizing and location, or risk of
sufficient mechanical force. This is achieved by
incorrect operation due to lack of alarm
supplying the cleaning liquid at fluid velocities
systems.
between approximately 1.5 to 3 m/s and
ensuring adequate contact time with the
2. A correctly designed process system: The
cleaning liquid. The required flowrate/s of liquid
process must be specifically constructed for
will vary according to the actual pipe sizes used
automated cleaning, e.g. radius of pipe bends,
in the pipework, or the size of the equipment.
self-draining equipment and pipework (including
For example; spray balls located and sized to
adequate support to prevent local sagging) and
ensure that all parts of the tank receive
no dead ends. An excellent CIP side will not
adequate cleaning force, and cleaning liquid
compensate for a poor process side.
pumped out at a rate that ensures the tank
3. Adequate maintenance: Poorly maintained CIP
remains empty. This ensures that the tank
systems can increase the contamination risk as
bottom can be contacted by the cleaning spray.
cleaning failures become less noticeable when
Typical CIP cycle
automatic systems are used (i.e. equipment is
rarely disassembled). Important requirements
Step Purpose
include: pump maintenance, regular calibration
checks, recalibration and periodic valve
Initial rinse Remove gross soiling.
maintenance. Professional advice should be
Cleaning chemical Remove attached soil. (Typically
obtained to assist in identifying the preventative
wash (often caustic, but also acid or other
maintenance requirements of a given CIP
repeated) types of chemicals).
system.
Rinse Remove cleaning chemicals.
Hygiene principles for CIP systems
Sanitise Reduce microbial load to a safe
level.
Effective cleaning relies on four main factors: time,
Final Rinse Remove sanitiser (unless using
temperature, concentration and mechanical force.
no-rinse sanitiser) and clear CIP
circuit of cleaning chemicals.
© Dairy Food Safety Victoria 2006 Page 1
Dairy Food Safety
Notes
CIP (Cleaning In Place) Systems
For reuse CIP systems, cleaning solutions may be
made up on demand, according to the required
application (i.e. these systems are often referred to
The diagram below shows Process Unit 2 being
as multiple applications). For example; 1-2% caustic
cleaned (Process Unit 1 closed off). Arrows indicate
solutions for tanks and heat exchangers, or 1%
dead areas where material can collect during
solutions for pipework, at the various temperatures
cleaning.
as required.
Example: Single-use CIP systems
Basic single-use systems include make-up tank/s, a
heating system (e.g. steam injection or heat
exchanger) and pump/s, connected into a suitably
designed process. These would be supported by
instrumentation and control systems.
The cleaning cycle begins with several rounds of
pre-rinse water to remove gross soil deposits and
minimise the cleaning task. For this step as well as
all the following steps, the number and duration of
each round is pre-determined, e.g. via cleaning
trials.
Next, the cleaning chemical is made up to the
required concentration and temperature, pumped
through the process for a set time and then sent to
Standard stop Standard stop
drain. Solution temperature and concentration are
valve (closed) valve (open)
typically monitored at one point (the end of the
processing line) but they can be monitored at two
These dead areas will contain a mix of cleaning
points (at make-up and on the return line) so that
chemicals, sanitiser and water which would
adjustments can be made as necessary. Similarly,
contaminate Process Unit 1 when the valves are
flow rates should be monitored using pressure
opened. In addition, Process Unit 1 is not protected
gauges or flow meters.
from chemical contamination in the case of valve
The system is then rinsed out and the process
leakages.
repeated for the acid wash, if used. Note that it is
Problem areas such as these can be eliminated by
extremely important that chemicals be rinsed out
good design. In very small and simple systems,
thoroughly. This is not only to prevent product
design issues and their solutions may be relatively
contamination or chemical inactivation, but also to
easy to identify, given sufficient time and process
prevent the interaction of for example an acid
design experience. However, larger systems require
cleaner and a sanitiser (e.g. hypochlorite) which can
a significant investment in professional advice and
react and produce harmful chlorine gas.
experience to prevent inadvertent contamination
The system is then sanitised and rinsed (final
risks. It is not recommended to design CIP and
potable water rinse). Time, temperature, flow rate
process systems without professional advice.
and concentration are monitored and controlled as
Types of CIP systems
before, to ensure that the cleaning cycle complies
with the intended program.
The two main types of CIP systems include:
Common issues
1. Single use: These do not reuse the cleaning
solution and are often limited to small systems
1. Verification: CIP system effectiveness must be
(i.e. servicing one or two pieces of equipment
validated initially, and then verified regularly.
and associated pipework). Typically used for
Methods: Visual inspection, swabbing and rinse
heavily soiled or critical hygiene processes.
water assessments.
2. Re-use: If the equipment being washed does
2. Unusual circumstances: e.g. Excessive build up
not tend to be heavily soiled, the cleaning
in a plate heat exchanger due to an extended
solution is re-used by adding more chemical
production run. The temperature of the heating
concentrate as required.
fluid rises to compensate, causing burn-on
which is subsequently not removed by the
standard cleaning program.
© Dairy Food Safety Victoria 2006 Page 2
Dairy Food Safety
Notes
CIP (Cleaning In Place) Systems
3. Monitoring and control: Inadequate process
monitoring to identify incorrect chemical
concentrations, times, temperatures or flow
rates, e.g. from blocked spray balls.
Recommended Reading
Lelieveld, H., L. M., Mostert M. A., Holah, J., and
White, B., (2003), Hygiene in Food Processing
Overview: Chapters 11, 10 & 8 1st edition,
Woodhead Publishing Limited.
Further information
Other Dairy Food Safety Notes are available at
www.dairysafe.vic.gov.au
Or contact:
Dairy Food Safety Victoria
info@dairysafe.vic.gov.au
tel (03) 9810 5900
PO Box 840
Hawthorn VIC 3122
This Dairy Food Safety Note has been produced in good faith by Dairy Food Safety Victoria. However Dairy Food Safety
Victoria does not warrant the accuracy of the information or accept the responsibility of any loss due to reliance upon the
information.
© Dairy Food Safety Victoria 2006 Page 3
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