Portable CIP: How Automated Cleaning Raises the Bar
What is a Compact CIP System?
A Compact CIP (Clean-in-Place) System is a mobile and automated industrial cleaning console designed to efficiently and effectively clean equipment and process lines in various industries, including food, beverage, and pharmaceutical. These systems are ideal for applications where space is limited and a small footprint is required. Compact CIP systems are cost-effective and can be customized to meet specific cleaning requirements.
The Compact CIP system is designed and engineered to provide consistent and repeatable cleaning results, ensuring high-quality products and minimizing the risk of contamination. The system features a user-friendly interface, allowing operators to program and monitor the cleaning process easily. The CIP program can be tailored to specific cleaning requirements, including temperature, rinse water, and cleaning agent concentrations.
One key benefit of Compact CIP systems is their ability to optimize cleaning cycles, reducing water and chemical usage while minimizing waste. The system’s automated design ensures that cleaning is performed consistently and accurately, reducing the risk of human operator error.
In summary, Portable CIP systems are mobile, automated, and cost-effective solutions that provide consistent and repeatable cleaning results. They are ideal for industries that require high-quality cleaning and sanitation systems.
Automated Cleaning: How the Compact CIP Raises the Bar
Sanitary processors must consistently, repeatably, and efficiently follow strict equipment cleaning requirements to maximize productivity and prevent costly disruptions like product recalls. No matter how many prescribed procedures or how rigorously they’re carried out, you probably know it’s impossible to perform manual cleaning to exacting standards.
If your cleaning process doesn’t produce consistent results from one cycle to the next, you can’t guarantee that cleaning is done to standard. And with Food Safety Modernization Act requirements, consistency, accuracy, and repeatability are more crucial than ever.
Wouldn’t it be great if there was a way to produce consistent and effective cleaning results every time? Thankfully, automated cleaning makes this possible.
Automated cleaning lets you see and record compliance with standards rather than merely carrying out procedures that can expose your process to inconsistencies. Automated Clean-in-place (CIP) Systems clean and sanitize equipment - sanitary process lines, vessels, piping, and more - where it is, without removal or disassembly.
Central States Industrial (CSI) developed its Compact CIP to give sanitary processors the advantages of automated sanitizing and cleaning with the added benefits of system mobility, repeatability with automated washes, and wash process value logging capabilities—all at an affordable cost. Mobile CIP systems offer flexible and efficient solutions for on-the-go cleaning in various industries, such as food and beverage and brewing.
Choosing the right mobile CIP cart for a production facility is crucial. Factors like size, water volume, and flow rate must be considered to ensure effective cleaning.
A Closer Look at The Compact CIP and Its Capabilities
Skid build and features:
- 100-gallon single 316/316L grade stainless steel tank and 304 stainless steel frame
- Six-inch caster wheels for easy mobility
- Small footprint – can be deployed in constrained spaces where larger units won’t fit
- Robust, accurate Endress & Hauser or IFM instrumentation
- 24v 120W power supply for Programmable Logic Controller (PLC) and instruments
Overview of the Compact CIP System: The Compact CIP System is designed to provide efficient and thorough cleaning for various process equipment. Ensuring effective cleaning requires an appropriately sized CIP cart to prevent issues such as vortexing, which can introduce air into the CIP pump and affect performance.
Key Components of Compact CIP: The system includes several key components that contribute to its effectiveness. One of these components is the use of spray balls to effectively clean process tanks up to 11' in diameter.
Key Components of Compact CIP
A compact CIP system comprises several key components that work together for efficient and effective cleaning. Each element is vital in ensuring the system operates smoothly and delivers consistent cleaning results. Understanding these components can help users optimize their cleaning processes and maintain high hygiene standards in their production facilities.
Caustic Fluids Directional Valves for Efficient Cleaning
Caustic fluid directional valves are a critical component of a compact CIP system. These valves are designed to direct the flow of caustic fluids to the tank or process equipment being cleaned, ensuring that the cleaning solution is delivered precisely and efficiently. The use of caustic fluid directional valves helps reduce cleaning time and improve the overall effectiveness of the cleaning process. By accurately controlling the flow of cleaning agents, these valves ensure that all surfaces are thoroughly cleaned, minimizing contamination risk and ensuring compliance with hygiene standards.
Supply and Return Temperature Monitoring
Temperature monitoring is another essential component of a compact CIP system. This assembly is designed to monitor and control the temperature of the cleaning solution, ensuring that it is maintained at a set temperature throughout the cleaning process. It records the temperature in both the supply and return and provides real-time data. This ensures that the cleaning process is both efficient and effective, resulting in consistently high levels of cleanliness and sanitation.
Controls and Automation of Caustic Fluids Directional Valves
The standard model Compact CIP runs a choice of five built-in wash cycles with one-button touch. PLC control of pump speeds, chemical concentrations, and temperatures ensures consistent wash results cycle to cycle. If any wash cycle parameters are unmet during a wash cycle, staff can see where deviations occur and take corrective action. Maintaining enough liquid in the tank is crucial to ensure adequate liquid levels and prevent vortexing. This is important to avoid introducing air into the CIP pump, which can affect system performance.
Standard system functions included are:
- Automatic tank level
- Start & stop
- Temperature controls
- Recirculation or forward flow routing.
Standard status indicators included are:
- High & low temperatures
- Flow and conductivity
- Pump failure-to-start alarm
- System active/idle
- E-stop active
The CIP’s user-friendly control panel, the Human Machine Interface or HMI, connects with the CIP’s PLC to execute the desired programs, making system configuration and day-to-day operations easy. The HMI features:
- Panelview 800 7” HMI touchscreen terminal
- Micro850 Programmable Logic Controller
- Stratix 2000 unmanaged Ethernet switches
- 2080 Series I/O Modules as needed for skid-mounted hardware
- PowerFlex 525 AC drives with embedded ethernet/IP™ communications, USB programming, and standard safety features
- Non-illuminated E-Stop, twist to release, mounted in the door
- 24v 120W power supply to power PLC and instruments
- Six-station air manifold with four solenoids for automated valves
- DIN rails, raceway and terminal blocks for panel wiring
- Stainless steel NEMA 4X enclosure
Clean-in-place Buying Guide
This Buying Guide for Clean-in-Place Solutions is a comprehensive resource for anyone who designs, owns, or operates processing systems and wants information about all aspects of CIP Systems.
With a client-supplied USB device installed, the standard-configuration system records wash cycle values, including CIP supply flow, supply temperature, return temperature, and chemical conductivity in .csv file format while cycles run. The .csv files can then be stored or imported into wash reports. CSI can also customize the Compact CIP to integrate it with supervisory system PLC either through hardwired or wifi connection.
This enables:
- Direct transmission of CIP data to supervisory PLC
- Remote monitoring and skid operation, including starting and stopping washes and tracking cycle phases, system alarms, and remaining cycle time remaining.
Optional/custom features:
- 30 kW electric heater for trim heating
- Automated caustic/acid dosing pump
- Return pump cart to reclaim CIP solution
- Stationary (rather than rolling) base if CIP is intended to be used in a single location – which allows for hard piping/wiring of water, power and CIP process lines.
- Custom wash programs to meet client-specific requirements
- Router/wifi antenna
- Programming to enable CIP integration with supervisory PLC
Benefits and Advantages of the Compact CIP at A Glance
| Eliminates human error – cycles are reliable and repeatable | Less than half the cost of a typical entry-level skid | Compact size and mobility mean Compact CIP can operate in tight spaces |
| Runs CIP independently, freeing operators to focus elsewhere | CSI’s vendor partnerships mean higher quality equipment at lower cost | Larger plants can dedicate Compact CIP to specific processing areas to prevent allergen crossover – after cycle completion water is sent to drain |
| Prevents employee exposure to chemicals | Repeatable cycle control saves water, energy, and cleaning agents - no over-cycling or overuse of cleaning chemicals to “make sure” | Solution for well-established plants that want to expand CIP capabilities - no commitment to an additional hard-piped, centralized system |
| Cleaning parameters validated and results recorded - can be communicated to supervisory system PLCs | Faster cleaning, less downtime for processing equipment | Can complement a centralized skid |
| Minimizes contamination risk– fewer recalls, higher consumer brand confidence | Smaller, budget-conscious businesses can take advantage of cutting-edge sanitary cleaning technology | With optional hardwire or wifi connection, data can be automatically transmitted to supervisory PLC and users can monitor and operation skid remotely |
| Less user and management time spent on operation, monitoring, addressing problems | Other optional features: 30 kW electric heater, automated caustic and acid addition, return pump cart to reclaim CIP solution, stationary base |
Next Steps
We know a Compact CIP system is a critical investment for your business, and we're here to help. CSI's skills and expertise include food, beverage, brewery, home and personal care, pharmaceutical, and biotech industries. We'll ensure your Compact CIP fits your specific hygienic processing needs and maximizes return on investment.
CSI's templates and configurators let us quote the cost for a customized Compact CIP project in minutes rather than weeks. We're also experts in meeting clients' needs for new equipment that integrates seamlessly with their business's existing equipment, operations, and training.
Every piece of equipment leaving CSI's manufacturing plant has undergone Level II inspection per the latest ASNT Recommended Practice No. SNT-TC-1A, so you can be sure your new Compact CIP meets industry standards. A factory acceptance test ensures systems are working correctly and allows you to try it out, ask questions, and request modifications.
We're here to help you learn how the affordable Compact CIP can make your business's sanitary processing more reliable and efficient.
ABOUT CSI
Central States Industrial Equipment (CSI) is a leader in distribution of hygienic pipe, valves, fittings, pumps, heat exchangers, and MRO supplies for hygienic industrial processors, with four distribution facilities across the U.S. CSI also provides detail design and execution for hygienic process systems in the food, dairy, beverage, pharmaceutical, biotechnology, and personal care industries. Specializing in process piping, system start-ups, and cleaning systems, CSI leverages technology, intellectual property, and industry expertise to deliver solutions to processing problems. More information can be found at www.csidesigns.com.