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CIP washing stations

We offer design, supply, installation and commissioning of CIP washing equipment for food processing plants. Our experts with more than 15 years of experience in the leading company AB InBev will help you modernise your production in line with global industry trends. We bring together the best process engineers who are passionate about their work with plant owners.

Problems with washing equipment

The quality of a product is its taste and safety, especially bacteriological safety.

Consumers don't see the production process and expect the manufacturer to comply with regulations and keep their lines clean.
But any equipment cleaning means forced downtime. Therefore, the manufacturer is interested in reducing its time without compromising product quality. The owner of the production facility wants to sell the products without returns. It is also important to him that the investment in the modernisation of the SIP system is recouped, and that the supplier does not "disappear from the horizon" after delivery. The producer's interest is to ensure the quality of beer without unnecessary costs.

The participants in the production process have their own problems and expectations from the cleaning process.

The task of local producers:
  • Инженер-технолог
    Process engineer
    is interested in reducing downtime and changing production plans as little as possible due to the wash. He wants to avoid conflicts in the maintenance schedule of different types of equipment, but not to wait for accidents and breakdowns. At the same time, the technologist wants to control the washing process without spending a lot of time on personal presence.
  • Технический специалист
    Technical specialist
    is interested in the reliability of the line. He expects that there will be no water hammer during the CIP wash, which can lead to breakdowns. He also wants to "understand" the equipment he is servicing. To do this, he needs an accurate operating manual and a match between the declared technical characteristics and the actual ones. And the energy consumption of the CIP washer - the actual consumption of electricity, heat and water - plays an important role.
  • Специалист по качеству
    Quality specialist
    wants to see the bottlenecks on the line. He needs the convenience of sampling for analysis, the absence of "dead zones", and the availability of records (logs) of the SIP washing process. He expects staff errors during the same preparation of cleaning solutions to be minimised.
The expectations of different participants in the production process during equipment cleaning can be combined into one list:

  • reduce downtime;
  • to achieve physical and bacteriological cleanliness of the line in order not to deteriorate the quality of beer;
  • prevent accidents;
  • control the washing process as much as possible without personal involvement;
  • reduce manual actions to avoid the influence of the human factor;
  • avoid resource overruns.
CIP (Cleaning in place) washing systems help to optimise the washing process in production. This is an automatic or semi-automatic CIP system for cleaning various types of food equipment without disassembling it.

Types of CIP stations

The CIP system consists of three parts:

  • CIP station;
  • distribution lines;
  • washing facilities.
In fact, there are only two types of IPP systems: centralised and decentralised.

The first type is most effective in small breweries, where the distance between the station and the cleaning facilities is small. Centralised systems are also common in those breweries where all CIP operations are performed from one location. It houses one CIP station or a group of them, and from there, detergents are delivered to different cleaning facilities.

Decentralised CIP systems are more common in large enterprises, where the distances from the central CIP station to the washing facilities can be very long. This type of equipment uses several distributed CIP stations located close to the washing facilities.

In food production, two-section CIP stations are often required, depending on the objects to be cleaned. The cleaning process is different for cold or hot surfaces. It is also advisable to separate the CIP washing of equipment for unprocessed products from lines with pasteurised products to avoid the spread of spores and surviving bacteria.

The main stages of CIP washing:
  • 1
    Removing product residues from equipment
    Scraping, draining, water or compressed air displacement are used.
  • 2
    Preliminary rinsing
    to remove any residual contamination and ensure physical cleanliness.
  • 3
    Washing with detergents
  • 4
    Rinse with clean water
    to remove residual alkaline or acidic solutions.
  • 5
    Sip sink
    disinfection with chemicals or heat for bacteriological purity. Not all types of CIP have this step.
The CIP sink for food production contains all the necessary equipment for preparing and storing cleaning solutions, distributing them to the cleaning objects with the correct flow and temperature, and finally controlling the cleaning process.

CIP sink for production - how to choose

The design of a CIP station is determined by many factors, so you need to know the answers to the following questions:
  1. How many separate cleaning circuits (i.e. equipment to be cleaned and distribution lines) will the plant serve?
  2. What are the requirements for the objects to be cleaned - for example, hot or cold surfaces?
  3. Will the rinse water and detergent solutions be recycled?
  4. Is the rinse water to be collected and then treated?
  5. What method of disinfection will be used: chemical, steam or hot water?
  6. What level of automation and control does the system need to provide?
  • will there be recipes and automatic cleaning programmes?
  • Is there a connection to the washing facilities?
  • local control or integration into a centralised control system?
Our experts will model the equipment washing process taking into account the needs of your production, offer optimal solutions, select equipment models and organise its delivery.
Why can you trust us?
Viravix Engineering is an expert community of process engineers in food production. Our specialists worked for more than 15 years at AB InBev, where they rose from an ordinary equipment maintenance worker to a zone expert responsible for 12 plants in different regions. We are known in the industry by name and are widely known by word of mouth.
Already on our own, we have implemented dozens of projects in Ukraine and Europe.
We used solutions ranging from mobile SIP sinks for small tanks to multi-circuit SIP stations operating in a fully automatic mode.

In designing our equipment, we use the best international practices in safety, quality and energy consumption from international manufacturers. Our partner is Elaks, whose specialists have been engaged in turnkey industrial automation for almost 30 years. They have carried out projects for Nestlé, Wimm-Bill-Dann and other major players in the food industry and the pharmaceutical market.
What do you get in cooperation with us?
At the stage of technical solution approval
  • individual approach to solving equipment design issues;
  • design and engineering of BMS systems based on the calculation of total operating costs;
  • making changes to the CIP system based on an accurate 3D model and specifications;
  • workshop with your specialists to work out the design of the CIP station, safety and ease of operation;
  • modelling the equipment washing process based on a 3D model of the washing circuit.
These are not empty promises. We will confirm our qualifications and experience with the necessary documents and cases.

Possible solutions for optimising the sink's CIP

First, we will install monitoring systems and, based on its data, identify personnel errors at all stages of work, "dead zones" on the line.

As a rule, these are the most frequent causes of all losses during the brewery's CIP washing process.
Based on the results of the observation, we will propose possible solutions. These may include:

  1. Consultations on the organisation of drainage and storage of cleaning solutions. Automatic sampling.
  2. Consultations on the causes of accidents and breakdowns. You will pay for them only if the problem requires in-depth specialist involvement.
  3. Free advice on how to eliminate splashing.
  4. Vibration analysis. Modification of the software of the carwash control system to receive notifications of a water hammer accident.
  5. Audit of the causes of water hammer and selection of technical solutions.
  6. Restoration of electrical circuits.
  7. Installation of permanent monitoring systems for data collection - external and internal, recorders.
  8. Development of "seasonal" modes of equipment operation.
  9. Audit of washing facilities and processes. Further recommendations, such as dilution of detergents.
  10. Technical support of equipment from selected suppliers.
We will find out which items from the list you need after studying the initial data about your production.
Your additional benefits
You will receive a remote monitoring system that will eliminate the need for your specialists to be present during the CIP washing process.

It has another advantage - you will save on the cost of our engineers visiting the site in case of incidents and accidents.
The specialist will be able to perform troubleshooting on the system data, analyse possible causes of failures and give technical recommendations remotely. The average savings on remote maintenance is €340 per incident.

Features at your choice:
  • automated communication between the SIP station and car wash facilities;
  • automation of the process of dosing detergents to ensure the safety of equipment without compromising the quality of cleaning;
  • development of various washing modes;
  • automatic analysis of resource consumption with an accuracy of 95%;
  • free support from the supplier in optimising washing processes;
  • organisation of an emergency shower.
We will make 3D models of equipment for you, and if necessary, perform a 3D scan of the premises. You will be able to see how best to arrange the SIP station in your production. If necessary, we will arrange for the installation of additional equipment and software to control the consumption of water, energy, and detergent concentrates.

Another advantage of working with us is that we offer only what can be delivered and where there will be no difficulties with components.

Leave a request to Viravix Engineering in any convenient way, and our specialists will contact you. Or call us if you have any questions.