Saving Water and Detergent Wastage in CIP with Baumer’s AFI Sensor

Updated: Mar 8

The ‘Cleaning In Place’ principle can be applied to any sector and factories where hygiene is of utmost importance.


What is CIP?


The ‘Cleaning In Place’ principle can be applied to any sector and factories where hygiene is of utmost importance.


The Health and Safety Legislation is may make the CIP process common to every plant and industry. This is a positive point because the glossy outer surface of the plant does not guarantee its cleanliness on the internal surfaces.


The CIP process basically more gravitates towards soil removal, which means anything that should not be inside a clean tank.


This is because it can contaminate and stink. It can be visible like foreign bodies, scales, etc., or even be invisible to naked eyes like bacteria.


It takes approximately 15 minutes to remove soil from the vessel using the right chemical at the right temperatures between a range of 50 degrees C and 75 degrees C.


Another plus point of this process in the food, dairy, and beverage sector is that it does not require any disassembling or removal of any equipment to carry on the process.

Benefits of the CIP System


The CIP system is highly beneficial and here are some of the positives that you can experience:


Minimizes Errors


One of the most important benefits of the CIP process is that it reduces the chances of human errors which can lead to an unsafe product.


Keeps the Workers Safe


Since the CIP is an automated process, it does not involve human intervention.


This decreases the chances of chemical exposure by containing the solution inside the system, thus keeping your employees safe


Improved Product Quality


This cleaning method is reliable as well as repeatable which means improved product quality.


This CIP process with AFI leads to less contamination which means fewer product callbacks and increasing brand goodwill.


More Production Time


As mentioned above, the CIP process takes only approximately 15 minutes to get the cleaning done. This means that less time is spent on cleaning, which results in more time in making the products.


Resource Savings


You can save a lot of resources like water and energy through reliable and repeatable CIP cycle control.


CIP Cleaning Cycle


Each CIP cycle runs as per its unique set of parameters, so we can say there is no ‘typical’ or ‘regular’ way of running the process.


The components, sequence, and the time taken vary but below mentioned are the common steps taht are included in every CIP cycle.


Pre-rinse


This is a very crucial step in the CIP cleaning process because a well-executed pre-rinse determines how well the following steps will take place. What does this step do:


● It wets the inside of the tanks and pipes

● It removes the remaining residue (most of them)

● It dissolves the sugars and melts fats partly

● It also delivers a non-chemical pressure test of the Cleaning In Place flow track


Caustic Wash


This step softens the fats, thus removing them faster. The caustic soda that is used in this process has a very high pH in a concentration range between 0.5 and 2.0%.


If the surfaces are highly soiled, then a concentration of 4% is used.


Caustic is the main detergent that is used in most CIP processes. It can help decrease pump cavitation, thus improving efficiency.


It also prevents the tanks from overfilling with foam at the time the system recirculates. This caustic wash can be re-used a number of times which saves water, energy, and chemical expenses.

Intermediate Rinse


Water removes out all the residues of detergents remaining from step 2. Using the right instrumentation at every step of this cycle is very important to ensure thorough cleaning.


Conductivity transmitters like Baumer’s AFI ensure the chemical levels are reaching the pre-determined level.


Last Rinse


This step involves a rinse with RO, DI, or city water to remove the remains of cleaning agents. In some systems, the water of the last rinse is re-used as the pre-rinse solution for the next cycle.


The chemicals and residual heat that it retains will make the pre-rinse of the next cleaning cycle more effective as well as affordable.


Sanitizing Rinse


This is the final step that may be needed to kill microorganisms before starting the production cycle.

Saving Water & Detergent Wastage in CIP with Baumer’s AFI Conductivity Transmitter


Water and Detergent Savings


Currently, water-saving is a huge hurdle in all industries. With Baumer’s AFI you can save water and detergent wastage.


The AFI conductivity transmitter detects a quick change in the media, thus saving water and detergent.


Case Study of positive results using the AFI sensor


An advanced facility at Baramati, Maharashtra, India has a massive production capacity of 1 million liters of milk daily.


This dairy plant uses the CIP process for cleaning and has 20 AFI4 installed for quick response time, saving resources and compactness.

Reduced Operation Costs


AFI installation for the CIP process ensures optimum utilization of resources and higher productivity.

Simplified CIP System


The process ensures a simple sensor configuration. Baumer’s AFI conductivity transmitter has a unique ready to fit design.

Food Safety


The AFI conductivity transmitter ensures thorough cleaning process control of the tanks and pipes.

Conclusion


As we know water and detergent wastage is a major problem in the dairy industry, the AFI can help you detect the change in media from water to acids quickly. This can help you save a lot of resources daily.

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