CIP Training Series CIP System Pin Charts Common

CIP Training Series CIP System Pin Charts Common Cleaning Steps of Clean-In-Place Systems Used by the Food Processing Industry Training For Sanitation Consultants and Plant Personnel

CIP Pin Charts CIP Functions z A CIP Program consists of a a series of programmed steps or functions carried out in the proper sequence z Each CIP step activates/energizes the components of the CIP system that are necessary to perform that step z For example, in the Pre-Rinse, the following CIP system components are activated: water rinse tank outlet valve, CIP supply pump, steam valve (to heat exchanger or tank), and return pump (if tank is being cleaned), and misc. piping circuit valves.

CIP Pin Charts Use of the CIP Grid z A Pin Chart is a method used to help understand a complete CIP program: All steps and component functions are listed z A grid (spreadsheet) is used showing each step in the order that it occurs z For each step all components are shown that are activated/energized (on/off) in order to carry out that step. This includes all pumps, valves, heat input, etc. z CIP system programs are laid out in a “Pin Chart”, especially in the design phase of a new CIP system (or for a new circuit placed on a current CIP system) z Pin Charts are used as a guide to enter programming instructions into a CIP system PLC

CIP Pin Charts Examples of Pin Charts Pin Chart examples are given to illustrate common CIP programs Four Examples Provided: z Truck (In-take Bay) Wash y 2 -Tank: Wash and Rinse tanks, Sanitize z Silo and Tank Wash Program y 4 -Tank—Rinse, Alkaline, Acid, Rinse Recovery z Silo and Tank Wash Program y 3 -Tank—Rinse, Alkaline, Rinse Recovery z Lines Wash Program y 4 -Tank—Rinse, Alkaline, Acid, Rinse Recovery All Programs include a sanitize step

CIP PIN CHART Truck Wash Program Example 1: 2 -Tank—Wash and Rinse

CIP PIN CHART Silo and Tank Wash Program Example 2: 4 -Tank—Rinse, Alkaline, Acid, Rinse Recovery Omit Last 2 Columns for 3 -Tank (no rinse recovery)

CIP PIN CHART Silo and Tank Wash Program Example 3: 3 -Tank—Rinse, Alkaline, Rinse Recovery For 2 -Tank System—Rinse & Alkaline Tanks—Omit Recov. Note: Pin Charts may have columns for level controls and other parameters. [In this chart 1 = energized]

CIP PIN CHART Lines Wash Program Example 4: 4 -Tank—Rinse, Alkaline, Acid, Rinse Recovery Note: Pin Chart may indicate low, mid, and high level control probes for each tank. Mid level control for recovery tank included for illustration.

CIP Pin Charts Pin Chart Programs Discussion & Comments Pre-Rinse Step Tanks: z The pre-rinse is the longest rinse step, since the line to the vessel must first be filled (with additional programmed time for rinsing) z Potable water used to prevent accidental contamination Lines: z A continuous potable rinse is done—no bursts z Time dependent on line size and legs z Return check validates circuit loop completed z A pause may be included (shut down) so that cleaning of valves and line connections can be done; the program is then restarted

CIP Pin Charts Pin Chart Programs Discussion & Comments Pre-Rinse Step Tanks: z In some cases for a re-use system, more than 3 burst steps may be needed due to soil carry-over. Soiled rinses must be pumped out before the next burst is done. z Evaluate if the alkaline wash tank solution is being impacted by chlorine reaction/depletion from chlorinated alkaline solutions z Need to determine: number of bursts needed, if the pump down time is long enough for complete evacuation, and if the rinse temperature is adequate to melt fats

CIP Pin Charts Pin Chart Programs Discussion & Comments CIP of Tanks Wash Step Re-use Systems: z The drain valve closes; the CIP wash tank outlet and inlet air valves open. The CIP supply pump circulates the wash solution out of and into the CIP wash tank (alkaline or acid). Single-use Systems: z Measured volume of water added. The loop is closed (drain valve and supply tank outlet valve closed, supply tank inlet valve open, pump on) z Program proceeds after return check confirms flow or pressure on CIP pump discharge, prior to addition of steam and chemical

CIP Pin Charts Pin Chart Programs Discussion & Comments CIP of Lines Wash Step Re-use Systems: z The wash tank return and supply valves are open, the drain valve is closed. Wash solution circulates through all of the line circuit and segments with valve cluster pulsing as needed. z A return check may be used to confirm a complete circuit has been completed before proceeding in the CIP program. Single-use Systems: z In line cleaning, the supply tank is used (unlike for tank/silo cleaning), since volume expansion from heating must be taken into account for pipelines (for tank/silo cleaning, the tank/silo allows for thermal expansion)—thus, the CIP tank inlet/outlet valves are open. z There should be a return flow check. (Note: For line CIP, the CIP supply tank is used for balance/surge control; in tanks, the vessel itself controls the balance/surge).

CIP Pin Charts Pin Chart Programs Discussion & Comments Drain & Post-Rinse Step Re-use and Single-use Systems Tanks: z Drain: The wash solution must be completely evacuated to prevent carryover of alkalinity (Na. OH or KOH) and chlorine (as Na. OCl), especially after the alkaline wash and prior to the acid wash. Toxic, corrosive chlorine gas may result (forming Cl 2). z Post-rinse: To validate, utilize p. H, conductivity, or check with a chlorine test kit (Na. OCl <5 ppm). z Rinse goes to drain/sewer or rinse recovery tank until it is approximately full. Lines: z Potable water is used (if the post-rinse is the final rinse). The CIP time depends on the piping circuit.

CIP Pin Charts Pin Chart Programs Discussion & Comments Sanitize Step Re-use Systems: Tanks & Lines: z Single-pass sanitizing method is usually used. Sanitizer is injected in line (usually suction-side of CIP supply pump) in correct ratio to flow. Sanitizing solution is pumped through equipment and lines to drain. z For lines, short injection step followed by air blow is done. For long line circuits, programmed injection time of sanitizer is longer as appropriate. z After sanitizing, draining of solution and/or airblow is done, the system is shutdown and the program is complete.

CIP Pin Charts Pin Chart Programs Discussion & Comments Sanitize Step Single-use Systems: z Potable water is charged to the supply tank, the drain valve is closed and the tank inlet and outlet valves are open. z Flow/pressure is confirmed prior to addition of the sanitizer for the step to advance.

CIP Pin Charts Pin Chart Programs Discussion & Comments Thank you for your time! Questions?