System Integration & Control Systems Design


Fully automated CIP system upgrade at a food factory

September 2020 System Integration & Control Systems Design

Hybrid automation was approached by one of its clients to work on a CIP upgrade project for a food production plant based on the East Rand of Johannesburg. The plant had an existing CIP system, which had drawbacks in terms of effectiveness, safety risks and excessive operation costs.

Principle of operation

The CIP plant operates by making up CIP medium into 6000 litre tanks, which contain cold water, hot water and CIP chemical solution. Once the CIP medium is prepared to the desired specifications, it is supplied via a storage tank to the factory equipment being cleaned. The storage tank has a return pump on the outlet to return the dirty water back to the CIP plant. This water, depending on its conductivity, will either go to drain or it will be recovered back into the CIP makeup tanks.

Challenges and solutions

The client had a number of challenges with regards to the existing CIP system:

Non-effective CIP

The existing CIP system was not effective in terms of cleaning equipment to desired standards and as a result the client had lost money in the market due to products failing to comply with certain food safety standards. This was the major factor contributing towards the upgrade project.

The upgraded CIP plant is equipped with high quality and reliable conductivity sensors that monitor all parameters during CIP make up and operation, therefore the equipment being cleaned is monitored to ensure effectiveness. The whole cleaning philosophy of the plant therefore evolved from being time-based on the old system to being effectiveness-based on the new one.

CIP cross contamination

Separation of CIP medium and product is very vital. The client had challenges in the past whereby these two mixed, which is also a quality compliance risk. To resolve the problem, the plant could only be cleaned on non-production days – mainly weekends.

The new design completely isolated CIP from production by the use of smart swing bend panels, which use inductive proximity sensors to detect port connections. The control system uses this information to manage all the relevant system interlocks to prevent cross contamination and most importantly, to ensure safety. This allows individual production plants to be cleaned independently during normal production days, without the possibility of getting CIP medium into other machinery that is in production mode.

Excessive operating costs

Apart from production time lost during plant CIP, there is a significant cost associated with running a CIP plant i.e., cost of chemicals, water bills, electrical bills etc. The old CIP system took longer as it was manually operated and the cost of chemicals was high as there was no recovery of CIP medium, everything was just going down the drain.

Generally, CIP process in a plant of this magnitude uses excessive amounts of water and consumes energy to heat it to the desired temperature. In addition, CIP chemicals are costly. The upgraded CIP is designed in such a way that CIP return from the equipment being cleaned can be recovered into the

CIP tanks rather than going to drain, which is an additional benefit to the client. The upgraded CIP system is also fully automated, which makes it easy to use and it lessens plant downtime.

The benefits

The primary goal of the project was to deliver an effective and efficient CIP solution. Therefore, throughout the commissioning phase and project signoff, the client’s quality department performed quality checks on every piece of equipment being cleaned, before and after CIP. The results came back positive, which proved that the new CIP system is effective and based on an efficient philosophy.


Credit(s)



Share this article:
Share via emailShare via LinkedInPrint this page

Further reading:

SCiBOTRON’s quality culture the key to success
May 2020 , System Integration & Control Systems Design
The company was founded on lean principles and quickly grew into a QSE (Qualifying Small Enterprise). Ricardo Paddy, managing director and founding member, attributes one of the reasons for the company’s ...

Read more...
Omniflex enables mine water quality
October 2020, Omniflex Remote Monitoring Specialists , System Integration & Control Systems Design
Water licences carry a ‘Burdon of Proof’ that the licence holder will not harm the environment or the water system through its activities. This covers the use of water from the system and the responsible ...

Read more...
Safe and efficient water and wastewater treatment
October 2020, Endress+Hauser South Africa , System Integration & Control Systems Design
Depending on the application and the industry, water needs to have different properties to ensure the quality of finished products and the overall safety of production.

Read more...
PC-based control monitors road tunnel with flexible scalability
October 2020, Beckhoff Automation , System Integration & Control Systems Design
With more than 200 industrial PCs in operation, the Kaisermühlen Tunnel in Vienna shows that scalable PC-based control technology from Beckhoff is an optimum automation platform in this environment.

Read more...
PC-based control reduces complexity in folio applications
October 2020, Beckhoff Automation , System Integration & Control Systems Design
BW Papersystems relied on PC-based control for the development of the eCon folio-size sheeter, which greatly reduced complexity and costs compared to the legacy system it replaced.

Read more...
Improved production capacity and efficiency
September 2020, Omron Electronics , System Integration & Control Systems Design
BOLÇİ Bolu Chocolate (Bolci) was formed in 1992. It now has over 300 employees and produces over 800 different products. The company produces over 200 tons of chocolate items each month in a factory that ...

Read more...
EtherCAT I/O for conveyor control
September 2020, Beckhoff Automation , System Integration & Control Systems Design
Integrated compact motor controller reduces cabling effort and increases diagnostic capabilities for roller conveyor systems.

Read more...
Robots could solve the social distancing problem
September 2020 , System Integration & Control Systems Design
While South Africa has seen a significant uptake in robotic technology, there are signs it will grow in the years to come as businesses make provision for these types of advancements.

Read more...
Machine upgrade at Rostberg
August 2020, Ana-Digi Systems , System Integration & Control Systems Design
Ana-Digi Systems designs and delivers a state-of-the-art, reliable machine upgrade to match its client’s requirements of easy setup and low maintenance.

Read more...
HMIs improve operations and maintenance collaboration
June 2020, Emerson Automation Solutions , System Integration & Control Systems Design
It is essential that operators and maintenance engineers work together to resolve issues quickly, before they affect plant performance. However, coordinating actions between these departments can be challenging.  ...

Read more...