Where liquids, pastes or bulk materials pass through enclosed systems, manual cleaning is virtually impossible: in tanks, pipework, heat exchangers, mixers and filling systems. This is where CIP comes into play – Cleaning in Place, i.e. cleaning whilst the equipment is in operation. The system remains fully assembled; cleaning solutions are pumped through pipes and distributed into containers via spray heads. This saves time, ensures that the cleaning process is reproducible and allows it to be documented.
CIP is best known in the food, drink and dairy industries. However, it is also used in pharmaceutical and cosmetics production, in the chemical industry, and in the manufacture of paints, varnishes and adhesives.
This is how a CIP clean is carried out
| Step | Purpose | A typical remedy |
|---|---|---|
| 1. Pre-rinse | Rinse out any large bits of food | Water, often reclaimed wash water |
| 2. Alkaline cleaning | Remove grease, protein, sugar and organic deposits | alkaline cleaner, usually used at elevated temperatures |
| 3. Rinsing in between | Rinse out all the lye | Water |
| 4. Acidic cleaning | Removing limescale, milk scale, beer scale and mineral deposits | acidic cleaner |
| 5. Rinsing in between | Rinse out all the acid thoroughly | Water |
| 6. Disinfection (if necessary) | Kill germs | Disinfectant or hot water |
| 7. Final rinse | Hand over the plant to production without leaving any residue | Product-grade water |
The steps required depend on the product and the plant. For light soiling, alkaline cleaning is sometimes sufficient. For heavy mineral deposits, the acidic stage is used more frequently. Some systems run the cleaning solution through just once (single-pass cleaning), whilst others collect it in tanks and reuse it several times (batch cleaning).
The four factors: chemistry, temperature, time and flow
The same applies to CIP: Sinner’s Circle. Instead of a brush and high-pressure jet, the flow of water takes care of the mechanical part here.
- Chemistry: Cleaning agent type and concentration. CIP systems often control the concentration based on the solution’s conductivity.
- Temperature: Many coatings come away much more easily when warm. However, temperatures that are too high can also cause the protein to burn.
- Time: the contact time per step. If you save time, you often have to compensate by adjusting the concentration or temperature.
- Mechanics (Fluid dynamics): In pipework, a turbulent flow is required. In tanks, the spray heads must reach all surfaces. Otherwise, deposits will remain in the spray shadow, dead zones and branch points.
What a CIP cleaner must be able to do
- Low-foaming: Foam interferes with pumps and spray heads and prevents the solution from wetting the surface.
- Easy to rinse off: No residues must enter the product.
- Compatible with materials: with stainless steel, seals and plastics in the plant.
- Temperature-stable: The effect must be maintained at the process temperature.
- Adjustable and measurable: so that the system can control the concentration reliably.
- Evidence: In the food and pharmaceutical sectors, for example, certificates of suitability.
- Wastewater: Alkalis and acids usually need to be neutralised before discharge.
Where Eco-Nova can help
We focus on the cleaning stages. Disinfectants are not part of our product range. The factor Chemistry We supply them ourselves: we have been developing and manufacturing our cleaning agents in Schüttorf for over 30 years, in containers up to 1,000-litre IBCs. As we manufacture the products ourselves, we can tailor our cleaning agents to the requirements of your CIP system, for example in terms of foaming behaviour, concentration or temperature range. The following might be suitable for the individual steps, for example:
| Task | Typical surfacing materials | Might be suitable |
|---|---|---|
| Alkaline cleaning | burnt-on residues, protein, fat, food scraps | Ultranova highly alkaline, characterised by |
| Acid cleaning of pipework and tanks | Limescale, mineral deposits, rust | Novascal coloured, marked; the colour-coding indicates the progress of the cleaning |
| Acid cleaning in food processing plants | Limescale, rust, mineral deposits | Meganova acid-resistant; with NSF or ISEGA certification |
| Circuit cleaning in the non-food industry | Oils, greases, pigments, light adhesive residues | Microsolv Plus low-foaming, dilutable; according to the MSDS, no hazard pictogram |
| Stubborn deposits, spray marks, dead spots | burnt-on or cracked coatings | individual, during the consultation |
These suggestions are a starting point. We will work with you during the consultation to determine which cleaner, concentration and temperature are best suited to your plant and your product, carrying out tests on your plant.
Mechanics, temperature and time are located on your premises. We can offer advice on this:
- We’ll work with you to identify which deposits are forming where and which step is required to remove them.
- We test cleaning agents and concentrations on your plant and compare them with your current range.
- We show where time, temperature or concentration can be adjusted without compromising the result.
- For parts that are not reached by the CIP system – such as spray heads, seals or removed fittings – we can find the right cleaning agent for manual cleaning.
- If there isn’t yet a suitable cleaner for your requirements, we will develop a bespoke formula (Tailor-made).
- We can provide documentation such as NSF or ISEGA certificates and declarations regarding SVHCs and REACH on request. For more information: Compliance and Certificates.
Common problems and what lies behind them
- The surfaces remain unchanged despite the programme: Often the flow isn’t right, there are spray shadows, or the temperature is too low.
- Foam in the system: The detergent is not low-foaming, or product residue foams up during the pre-rinse.
- Limescale and mineral deposits build up: The acid cycle isn’t running often enough, or the water is very hard.
- Burnt egg white in heating elements: Excessively high temperatures during the alkaline stage or production runs that are too long.
- High consumption of water, chemicals and energy: It is worth taking a look at batch cleaning, recovery and optimised parameters.
Always follow the instructions in the safety data sheet. Alkaline and acidic CIP cleaners are often classified as corrosive and require the use of protective equipment as specified in the safety data sheet. The safety data sheet is available on request to existing customers and to customers who have received a sample or attended a demonstration.
Is your CIP cleaning taking too long, using too much cleaning agent or leaving a residue? Tell us about your plant, product and your current cleaning programme. Our technical advisers will recommend a cleaning agent, put together some samples and, if you wish, visit you on site.