THE PLANT ENGINEER’S

GUIDE TO
SPECIFYING CIP SYSTEMS

IN THIS eBOOK
If you’re looking to automate the cleaning of a system,
or need to make changes to your current system, you’ve
come to the right place.

In this eBook, you’ll be guided through each factor you

must consider to properly specify a CIP system.
 THE PLANT ENGINEER’S GUIDE TO SPECIFYING CIP SYSTEMS

Content Inside
Benefits of CIP Systems / Effects of Poor Design
When done right, CIP systems can be an invaluable part of your operation. But
when left to inexperienced builders, the money they save can go down the drain.

Components of CIP System Specification

Eighteen essential components to consider when specifying your CIP system.

Conclusion

About the Author

Mike Brandt is an Account Manager at Crane Engineer-
ing with a long history of cleaning system experi-
ence. His past history includes coordinating and
planning the design, fabrication, and installation
of dozens of Clean In Place, Steam In Place,
and other process systems for the food and bev-
erage, biotech, and pharmaceutical industries.

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 THE PLANT ENGINEER’S GUIDE TO SPECIFYING CIP SYSTEMS

cip puts clean on auto-pilot

But if improperly specified, it doesn’t clean much of anything.

Manual cleaning of tanks, lines, blenders, mixers and other process equipment can be
a costly, time consuming chore. Operators are paid to be cleaning, while they could be
doing other, more productive tasks. Implementing a CIP system frees up more time for
operators while providing an extremely reliable and consistent cleaning result.

Oftentimes, businesses try to build CIP systems themselves or utilize a contractor or small
shop to build it. Seriously, how hard can it be? Just some tanks, pumps, and pipe all
hooked together, right? What less experienced system designers/builders may not real-
ize is that if tanks are not sized properly, flow rates are not accounted for, incorrect heat-
ing methods are used, etc., they’ll have a system that doesn’t clean much of anything.

In fact, poor design and fabrication can lead to:

• Equipment not cleaned properly
• Longer cleaning times
• Wasted chemicals and water
• Wasted utilities, such as steam

To get the most return on your investment, make sure you’re taking into account the fol-
lowing CIP system specification components.

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 THE PLANT ENGINEER’S GUIDE TO SPECIFYING CIP SYSTEMS

Components of CIP system

specification
1. SOIL TYPES AND CONDITIONS
What are we cleaning? Identifying the soil types and conditions is essential to de-
termining the flow rate of the CIP system, as well as the chemical required for the
cleaning process. Soil types and conditions consist of:

• Heavy – Dried and semi-dry carbohydrate material, ground and emulsified

meats, wet and semi-dry protein deposits (e.g. cheese)

• Moderate – Wet carbohydrates, dried liquids with suspended and dissolved

solids, fats and oils, wet and semi-dry fruit material

• Light – Dry ingredients, liquids with dissolved and suspended solids, fresh wet
vegetable or meat product (not emulsified or ground), dirt and extraneous
non-food material

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 THE PLANT ENGINEER’S GUIDE TO SPECIFYING CIP SYSTEMS

2. Identify which Equipment Requires Cleaning

Different types of equipment require different flow rates and pressure for effective
cleaning. Cleaning equipment other than tanks and lines requires additional engi-
neering in order to specify the flow rates and pressure needed.

Additional equipment that may need to be identified:

• Tanks • IBCs
• Lines • Blenders
• Fillers • Vats
• Mixers • Ovens
• Coaters • Freezers
• Spray dryers

3. Determine Number and Size of Tanks to be Cleaned

Before the size and quantity of CIP tanks can be specified, the dimensions of the
tanks and lines to be cleaned must be identified. This information will also help to
determine the flow rate and pressures that the system will need to overcome.

Tallest vertical Tank Height (in.) x Diameter (in.)

Largest Horizontal Tank Length (in.) x Diameter (in.)
Longest CIP Supply Line Diameter (in.) and Length (ft.)
Largest Diameter Process Line Diameter (in.) and Length (ft.)
Longest Process Line Diameter (in.) and Length (ft.)

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 THE PLANT ENGINEER’S GUIDE TO SPECIFYING CIP SYSTEMS

4. Frequency of Cleaning
The frequency of cleaning depends solely on the application. The industry and the
length of the processes will determine how frequently the system will need to be
cleaned. Cleaning could vary from ever 6-12 hours, to every other week or month.

Determining the frequency of cleaning will help determine which type of CIP system
should be used.
• Single-tank
• Two-tank
• Multi-tank
• Re-use
• Once-through
• Multi-circuit

5. Cleaning Time Limitations

When there’s little time for cleaning, options can be included in the system design
to limit cleaning time as much as possible. Additional tanks, recirculation capabili-
ties for heating/mixing, greater heating capacity, and/or multi-circuit capabilities
could all be included.

6. Return Method
Centrifugal return pumps, liquid ring pumps, or eductors are all efficient means of
returning fluid to the system. If using existing pumps, make sure they are sized for
10% above the flow rate of the system at a lower RPM.

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 THE PLANT ENGINEER’S GUIDE TO SPECIFYING CIP SYSTEMS
7. Heating Media
Heating media are different methods
or equipment used to transfer heat
from one medium to another. The me-
dia may be separated by a solid wall
to prevent mixing, or they may be in
direct contact.
The utilities available will determine
the method used.
• Steam: Most effective and ef-
ficient means for heating CIP
solutions
• Electrical: Can be very costly,
and takes a significant amount
of time to get up to temperature
• Natural Gas: Used only if
there’s no steam and a plentiful
gas supply
8. Heating Equipment
Most facilities have standardized
how they can heat media. The most
common method is through a heat
exchanger (shell & tube, or plate &
frame construction). Some facilities
choose direct steam injection to save
money on the front end. However, this
method does not allow for the capture
of condensate for re-use. Other meth-
ods include:
• Electric Heater – Installed
in the discharge of the supply
pump. Can be very inefficient
and brings excessive long term
costs in regards to AMP draw,
especially in situations where
ambient water will be used at
very high temperatures.
• Submersed plate – Use in CIP
systems is very rare, usually only
used in washers.
• Steam coils – Use in CIP
systems is very rare, usually only
used in washers.
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9. Supply and Return Valves

Each industry has different standards when it comes to supply and return valves. For
example, in the dairy industry, open yoke valves are required to meet 3A require-
ments, while most pharmaceutical companies must use diaphragm valves. Stringent
requirements like these are not in place for industrial applications or simple food
and beverage plants, where butterfly and ball valves are often used to reduce cost.

10. Additional Valving Features

Additional features can be used in a CIP system for improved efficiencies:

• Air-Blow – Used to clean out the lines for the CIP system to ensure it has
been fully drained of the previous CIP cycle.

• Throttling – Valves can be used as flow control instead of a VFD. They

can be controlled with a flow meter to ensure correct flow rates for cleaning.

• Burst Rinse – Another method of cleaning in which CIP solutions are burst
through spray balls instead of continuous flow.

• Drain – Most CIP systems include a drain valve on the suction and return to
help drain the lines. Some CIP systems will have drain valves on the CIP tanks
to speed up the draining process.

• Recirculation for Pre-Heating – Recirculation loops reduce cleaning

times, getting solutions up to temperature faster. They also help to get mix
chemicals at the proper concentration for cleaning.

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11. Chemicals
For the most effective and efficient cleaning, the right chemicals must be chosen
for the application. It should be noted that all chemicals for CIP systems need to be
non-foaming.

Examples of chemicals used in CIP systems:

• Detergent or caustic is used in most CIP systems. Sanitizer and acids

are traditionally the last thing to be utilized if needed.

• Acid is used in the cleaning process to help eliminate lime build-up in lines
and tanks, especially if hard water is used.

• Facilities can use extremely hot water (165° - 185°F or higher) as a sani-
tizer, or a chemical sanitizer – depending on the product and standard
operating procedures.

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12. Re-Use of Solutions

Depending on soil residue and company guidelines, a reuse system for chemicals and
water can be used to save money. Oftentimes, CIP systems can be designed to reuse
post-rinses that finalize a CIP cycle, using them as the first step of another CIP cycle as
the pre-rinse. In some industries, such as pharmaceutical, a single-use system will be
utilized because reusing chemicals or water is against standards set forth by govern-
ment agencies.

13. Type of Tanks

Tank requirements are largely dependent upon the industry. Atmospheric tanks are a
standard in most food and beverage industries, while ASME tanks are often used in
the pharmaceutical industry. Insulated tanks are more costly up front, but save money
in the long-term.

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14. Controls
CIP systems can be specified as fully automated or manual, depending upon plant
standards, cleaning frequencies, and operator safety and experience.

Some controls to consider are:

• PLC

• Operator’s Interface: HMI or visual screen to allow operator to check the sta-
tus of the cleaning and control the system using a touch screen or keypad

• Data Communication Interfaces: Allows the CIP system and its components
to communicate with a central system that records information and transfers
information.
-- RS-232
-- Ethernet
-- Data Highway +
-- Data Highway 485

• Data Recording (Supply and/or Return): Sometimes required for customers,

as well as a plant’s own standards to prove cleanings. Temperature, flow rate,
pressure, and conductivity are just a few things that could be recorded.

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15. Installation Area

Be sure to consider where the new system will be installed. Will you need a wash-
down motor on pumps? Is the area hazardous, where an explosion proof motor
should be used? The area determines what types of controls, motors, etc. you will
use on your system.
• Wet • Hazardous
• Sterile -- Class
• Non-Sterile -- Division
• Wash-down -- Group

16. Dimensional Limitation

Understanding the dimensional limitations of the of the installation area will dictate
the footprint of the CIP system and how modular the system needs to be to get into
the facility and installed. In some cases, the system may need to be re-assembled in
order to be installed.

• System limitations (length, width, height)

• Site access limitations (length, width, height)

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17. Additional System Design

Below are examples of additional information needed to work towards finalizing
the CIP system. A simple CIP system may have a motor starter or disconnect if it’s
cleaning at one flow rate and pressure that will not change, but this is rarely the
case. Most likely the system will utilize a VFD or throttling valve to control the flow
rates for the different circuits to be cleaned whether its tanks, lines, or other equip-
ment. Conduit is important to abide by standards of the different industries and
facility requirements.
• Spray Balls – An option for CIP systems to pass the returns or water supply
through to keep the CIP tanks clean
• Valve Position Switches – Indicates that a valve is functioning the way it
should and also provides an alarm on automated CIP systems to problems
can be addressed
• Audible alarm
• Gauges (Temperature and/or Pressure; Supply and/or Return) – Indicators at
the skid versus using analog sensors to feed back to the PLC
• Modem
• Printer
• Vent Filter
• Starter/Disconnect or VFD
• Conduit Type (Electrical and Air)
-- Stainless
-- Rigid
-- PVC Coated

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18. Utilities
To finalize the CIP design, the facility must be aware of the utilities available at the
plant. This will determine system functionality, as well as ensure the final design is
optimized for efficiencies and effectiveness.
• Heating
-- Plant Steam
-- Condensate Return
-- Clean Steam
-- Culinary Steam
-- Hot Water
• Cooling
-- Cooling Chilled Water
-- Cooling Chilled Glycol
• Drain
• Water
-- Plant Cold Water
-- Plant Hot Water
-- RO/DI Water
-- Hot WFI Water
-- Cold WFI Water
• Electrical
-- 1-Phase Power
-- 3-Phase Power
• Air
-- Plant Air
-- Instrument Air
-- Process Air

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Conclusion
When it comes to CIP, don’t DIY.

For industries that require high levels of hygiene, CIP systems can be an indispensable
piece of the system. They make cleaning faster, less labor-intensive, easily repeated, and
can reduce workers’ exposure to chemicals. But if improperly specified, all the money
you were supposed to be saving can go right down the drain.

Make sure you get more return on your investment by taking all of the above into con-
sideration and hiring a knowledgeable, experienced vendor to build your CIP system.
Working together, and with proper planning you’ll create a system that will provide reli-
able, worry-free service for years to come.

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