Mobile cip station unit

Introduction & Application

VIRAVIX offers a manually operated mobile CIP unit for small plants, where a high level of automation is not necessary, to facilitate the cleaning of these plants, to remove the impurities and to reduce bacterial presence. Also, this is why, when thinking about small facilities that require a certain level of automation, VIRAVIX designed an automatic CIP system to help to clean plants, eliminate impurities, and reduce bacteria levels.

Hygiene is an essential factor in the food processing, cosmetics and pharmaceutical industries. Cleaning in Place is considered another stage of the production process. In the foodprocessing industry a defective cleaning causes contamination of the product and affects its quality, also incorrect cleaning in the food industry can lead to the loss of an entire day’s production and directly affect the end product’s quality.

Structural Framing

• Design: Closed square/round tubing
• Surface Finish: Bead blasted
• Material: 304 square/round tubing
• Fully welded single piece construction.

Sanitary Piping

• Material: 304/316 sanitary tube and fittings
• Surface Finish: 0.8Ra
• Valves: Butterfly type, 304/316 body, EPDM and manual/electric/air/ actuator

Buffer tanks

• Volume: 600-1000l
• Tank sidewall insulation: no/yes with 304 sheathingTank sidewall insulation: no/yes with 304 sheathing
• Interior and exterior finish: 0.8 Ra with weld color removed frame
• Material: AISI304 or AISI316
• The tank(s) are mounted to the CIP frame.

Local Chemical Addition

There are three (3) options for adding local chemical addition to the skid:

• Manual chemical addition may be required
• Local Chemical Pump Assembly & (1) Chemical Reservoir with Low-Level Switch
• Local Chemical Pump Assemblies & (2) Chemical Reservoirs with Low-Level Switches

The chemical pump assembly doses the cleaning chemicals and/or sanitizer from a storage drum to the injection point on the CIP system. The concentrations are controlled to a time based setpoint value or to a conductivity setpoint value if the Conductivity Monitoring/Control option is chosen. The chemical pump assembly(s) are mounted to the CIP frame.

Chemical Reservoirs with Low-Level Switches – the reservoir provides an on-skid location to store chemical for use in the cleaning cycle. Quick disconnects make the reservoir easy to remove for filling. A level switch is integral to the assembly, providing a low-level alarm.

Heating System

Electrical heating method is provided. The system will wash the target equipment using water at the temperature supplied.

• Heat Exchanger – Steam

The Heat Exchanger – Steam option, a shell & tube or PHE heat exchanger provides indirect heating of the wash solutions. The heat exchanger will be located in the discharge of the supply pump.

• Electric Heater – 30 kW

The Electric Heater – up to 30 kW option adds an immersion style electric heater to the system. The electric heater is sized to maintain or minimally raise the temperature of the wash solution (up to 90˚C) and is dependent on the system being filled with water already at or above the desired wash temperature. The electric heater will be located in the discharge of the supply pump

Control System

The electrical cabinet and components used to control the system and is skid mounted.

• Schneider/Allen-Bradley/Siemens/Delta’s PLC with associated digital and analog outputs
• Frequency converter (for CIP Supply pump)

Operator interfaces can include the HMI and other components installed on the control panel.

• Schneider/Allen-Bradley/Siemens/Weintek/Delta with color 5”,7” touchscreen, Operator Terminal (HMI)
• Illuminated emergency stop/reset/LOTO switches

Reporting & Remote access

• QVisor- Data Acquisition & Management System
• TeamViewer IoT – Online Data Acquisition & Management System

Cleaning Cycles

The following phases are an example of a typical CIP cleaning cycle. Water fill, water drain, chemical addition, and/or heating steps are not listed but can be part of the phases. All cleaning steps are setup as individual operation codes enabling full customization of cleaning cycles.

• Pre-Rinse
• Rinse
• Caustic Wash
• Final Rinse (With or Without Sanitizer)
• Acid Wash

System Automation Programming of the HMI and PLC provide automation of the system.

• Cleaning sequences will be automatically controlled through the use of cleaning cycle recipes.
• Each recipe has its own setpoint values (e.g., time, temperature, conductivity, flow) which are adjustable
• Measured process variables have alarms with adjustable high/low setpoint values

Benefits & Advantages

The mobile CIP station by VIRAVIX has been designed with mobility and versatility in mind. Touch screen options , the program with built-in clean cycles, PLC interface to control pump speed and consumption , chemical concentration and temperature for consistent results. By automating the cleaning procedure with a mobile CIP, a plant can reduce cleaning time, reduce downtime, and increase repeatability through process parameters.

Structural Framing

• Design: Closed square/round tubing
• Surface Finish: Bead blasted
• Material: 304 square/round tubing
• Fully welded single piece construction.

Sanitary Piping

• Material: 304/316 sanitary tube and fittings
• Surface Finish: 0.8Ra
• Valves: Butterfly type, 304/316 body, EPDM and manual/electric/air/ actuator

Buffer tanks

• Volume: 600-1000l
• Tank sidewall insulation: no/yes with 304 sheathingTank sidewall insulation: no/yes with 304 sheathing
• Interior and exterior finish: 0.8 Ra with weld color removed frame
• Material: AISI304 or AISI316
• The tank(s) are mounted to the CIP frame.

Local Chemical Addition

There are three (3) options for adding local chemical addition to the skid:

• Manual chemical addition may be required
• Local Chemical Pump Assembly & (1) Chemical Reservoir with Low-Level Switch
• Local Chemical Pump Assemblies & (2) Chemical Reservoirs with Low-Level Switches

The chemical pump assembly doses the cleaning chemicals and/or sanitizer from a storage drum to the injection point on the CIP system. The concentrations are controlled to a time based setpoint value or to a conductivity setpoint value if the Conductivity Monitoring/Control option is chosen. The chemical pump assembly(s) are mounted to the CIP frame.

Chemical Reservoirs with Low-Level Switches – the reservoir provides an on-skid location to store chemical for use in the cleaning cycle. Quick disconnects make the reservoir easy to remove for filling. A level switch is integral to the assembly, providing a low-level alarm.

Heating System

Electrical heating method is provided. The system will wash the target equipment using water at the temperature supplied.

• Heat Exchanger – Steam

The Heat Exchanger – Steam option, a shell & tube or PHE heat exchanger provides indirect heating of the wash solutions. The heat exchanger will be located in the discharge of the supply pump.

• Electric Heater – 30 kW

The Electric Heater – up to 30 kW option adds an immersion style electric heater to the system. The electric heater is sized to maintain or minimally raise the temperature of the wash solution (up to 90˚C) and is dependent on the system being filled with water already at or above the desired wash temperature. The electric heater will be located in the discharge of the supply pump

Control System

The electrical cabinet and components used to control the system and is skid mounted.

• Schneider/Allen-Bradley/Siemens/Delta’s PLC with associated digital and analog outputs
• Frequency converter (for CIP Supply pump)

Operator interfaces can include the HMI and other components installed on the control panel.

• Schneider/Allen-Bradley/Siemens/Weintek/Delta with color 5”,7” touchscreen, Operator Terminal (HMI)
• Illuminated emergency stop/reset/LOTO switches

Reporting & Remote access

• QVisor- Data Acquisition & Management System
• TeamViewer IoT – Online Data Acquisition & Management System

Cleaning Cycles

The following phases are an example of a typical CIP cleaning cycle. Water fill, water drain, chemical addition, and/or heating steps are not listed but can be part of the phases. All cleaning steps are setup as individual operation codes enabling full customization of cleaning cycles.

• Pre-Rinse
• Rinse
• Caustic Wash
• Final Rinse (With or Without Sanitizer)
• Acid Wash

System Automation Programming of the HMI and PLC provide automation of the system.

• Cleaning sequences will be automatically controlled through the use of cleaning cycle recipes.
• Each recipe has its own setpoint values (e.g., time, temperature, conductivity, flow) which are adjustable
• Measured process variables have alarms with adjustable high/low setpoint values

Design

Technical information provided within this document is for VIRAVIX ’s c onfigured d esign o ffering of the mobile CIP – a small, portable, 1 or 2 tank s Clean-In-Place (CIP) system by VIRAVIX designed for the food, beverage, personal care, or nutraceutical industries. Alternative d esign r equests for variations in construction, size, component manufacturers, options, orientation, or other technical requirements should be directed to a VIRAVIX representative or a sales channel for custom quoting and engineering.

Technical data

The mobile CIP unit can be used for a cleaning-in-place a variety of process equipment, including process tanks, process piping, hoses, and more. Delivering up to 30m 3 /h at 5bar of CIP Supply Flow, the mobile CIP unit can be used for cleaning:

• Process tanks up to 10m3 for static spray operations
• Process lines up to DN80 diameter
• Process equipment

Structural Framing

• Design: Closed square/round tubing
• Surface Finish: Bead blasted
• Material: 304 square/round tubing
• Fully welded single piece construction.

Sanitary Piping

• Material: 304/316 sanitary tube and fittings
• Surface Finish: 0.8Ra
• Valves: Butterfly type, 304/316 body, EPDM and manual/electric/air/ actuator

Buffer tanks

• Volume: 600-1000l
• Tank sidewall insulation: no/yes with 304 sheathingTank sidewall insulation: no/yes with 304 sheathing
• Interior and exterior finish: 0.8 Ra with weld color removed frame
• Material: AISI304 or AISI316
• The tank(s) are mounted to the CIP frame.

Local Chemical Addition

There are three (3) options for adding local chemical addition to the skid:

• Manual chemical addition may be required
• Local Chemical Pump Assembly & (1) Chemical Reservoir with Low-Level Switch
• Local Chemical Pump Assemblies & (2) Chemical Reservoirs with Low-Level Switches

The chemical pump assembly doses the cleaning chemicals and/or sanitizer from a storage drum to the injection point on the CIP system. The concentrations are controlled to a time based setpoint value or to a conductivity setpoint value if the Conductivity Monitoring/Control option is chosen. The chemical pump assembly(s) are mounted to the CIP frame.

Chemical Reservoirs with Low-Level Switches – the reservoir provides an on-skid location to store chemical for use in the cleaning cycle. Quick disconnects make the reservoir easy to remove for filling. A level switch is integral to the assembly, providing a low-level alarm.

Heating System

Electrical heating method is provided. The system will wash the target equipment using water at the temperature supplied.

• Heat Exchanger – Steam

The Heat Exchanger – Steam option, a shell & tube or PHE heat exchanger provides indirect heating of the wash solutions. The heat exchanger will be located in the discharge of the supply pump.

• Electric Heater – 30 kW

The Electric Heater – up to 30 kW option adds an immersion style electric heater to the system. The electric heater is sized to maintain or minimally raise the temperature of the wash solution (up to 90˚C) and is dependent on the system being filled with water already at or above the desired wash temperature. The electric heater will be located in the discharge of the supply pump

Control System

The electrical cabinet and components used to control the system and is skid mounted.

• Schneider/Allen-Bradley/Siemens/Delta’s PLC with associated digital and analog outputs
• Frequency converter (for CIP Supply pump)

Operator interfaces can include the HMI and other components installed on the control panel.

• Schneider/Allen-Bradley/Siemens/Weintek/Delta with color 5”,7” touchscreen, Operator Terminal (HMI)
• Illuminated emergency stop/reset/LOTO switches

Reporting & Remote access

• QVisor- Data Acquisition & Management System
• TeamViewer IoT – Online Data Acquisition & Management System

Cleaning Cycles

The following phases are an example of a typical CIP cleaning cycle. Water fill, water drain, chemical addition, and/or heating steps are not listed but can be part of the phases. All cleaning steps are setup as individual operation codes enabling full customization of cleaning cycles.

• Pre-Rinse
• Rinse
• Caustic Wash
• Final Rinse (With or Without Sanitizer)
• Acid Wash

System Automation Programming of the HMI and PLC provide automation of the system.

• Cleaning sequences will be automatically controlled through the use of cleaning cycle recipes.
• Each recipe has its own setpoint values (e.g., time, temperature, conductivity, flow) which are adjustable
• Measured process variables have alarms with adjustable high/low setpoint values