We want to share our experience of how we reduced the cost of the keg filling line by 23% just by optimizing the cleaning process. At the same time, the quality of the product was not affected - with CIP the risks of bacterial contamination are minimized due to the absence of the human factor influence.
The client is the Ukrainian brewery Umanpivo. The production was founded in 1878.
For several decades, the plant has been producing the Waissburg, Zhigulevskoye brands, a number of beers according to its own recipes, cider, and lemonade.
Umanpivo actively cooperates with German brewers.
Tasks and objectives
The customer wanted to manufacture, install and commission a CIP station for cleaning the CENTEC pasteurizer and keg filling line in the new brewery premises.
The tasks he set for VIRAVIX engineers:
- Provide the required liquid flow rate with a long length of pipelines for cleaning with a significant difference in height.
- Compensate the lack of staff' experience in operating the new pasteurizer and filling line washer . Provide the maximum automation level.
- Ensure prompt change of equipment settings for high-quality preparation of cleaning solutions and disinfectant in automatic mode depending on the season.
- Integrate into the equipment a modern cleaning parameters monitoring system.
- Provide a possibility for further CIP station upgrades and enhancement with additional equipment.
- Optimize the consumption of hot water for cleaning, taking into account seasonal prevalence.
- Ensure fully automatic operation of the CIP station.
We installed the QiVisor remote monitoring system, a proprietary technology, on the existing equipment. This is a convenient and simple program that helped us collect initial data on the technological process and identify bottlenecks.
Based on the collected data, we analyzed the features of production and suggested the customer to use:
- Vessel equipment - Milesta.
- Stop valves – GEA.
- Steam fittings – ADCA.
- Pipe fittings – NIOB.
- Branch pipes for chemistry – Ecolab.
- Sensors – IFM, Endress & Hauser,
- Indicators – WIKA.
- Flow rate meter, conductivity instrument – Endress & Hauser.
- CIP pump – GEA.
- Chemical pumps – Yamada/Steiner.
- Heat exchanger – Schmidt-Bretten.
- Controller – Siemens.
- Monitoring system – QiVisor WE.
- Remote access equipment component –TeamViewer.
- Electrical-installation equipment – Elaks.
We will tell you what we have done in line with each task of the customer. But we will immediately warn you that it will not work to copy and repeat our experience completely. Each brewery is different, and technical solutions must be selected based on the operating conditions of the equipment.
Task 1. Provide the required liquid flow rate with a long length of pipelines for cleaning with a significant difference in height
For effective CIP cleaning, equipment is needed that will ensure a stable flow rate of the washing liquid in the pipe of at least 1.5 m/s. To select it, we took into account the following factors:
- places of possible leaks and fluid resistances;
- the number and size of pipeline restrictions;
- presence and parameters of filters;
- speed losses in heat exchanger sections;
- volumes of vessels for the preparation of the cleaning mixture;
- the presence and number of check valves;
- parameters of booster pumps for washing solution;
- cleaning equipment circuits.
As a result, the system automatically regulates the pump speed and controls the flow rate in the pipe without personnel intervention. A stable rate of at least 1.5 m/s is provided.
Task 2. Compensate the lack of staff' experience in operating the new pasteurizer and filling line washer . Provide the maximum automation level
The new CIP station was intended for cleaning:
- pipeline for product supply from the bright beer storage facility and the lantern block;
- both holding circuits of the CENTEC pasteurizer with a capacity of 160 hl/h;
- three filling lines into MINOMAT kegs by KEG Technik.
We took into account that the state of the flow can be affected by the position of the valves, the serviceability of the elements and the tightness of the cleaning system. Therefore, a special control sensor was installed in the return circuit pipe. If, with a working CIP station, there is no flow in the return pipe, the program will report this in the emergency mode. A sight glass was installed in the pipe for visual control of the liquid.
During the cleaning process, the solution may cool down. Its dilution with hot water leads to an increase in volume and a decrease in the concentration of detergents. To control the temperature, proportion and amount of solution, we installed sensors for temperature, concentration and liquid level.
When the level in the concentrate tank drops, the system issues a warning, reminding you to replace the tank in a timely manner. And when emptying, it reports an error, goes into emergency mode and stops cleaning.
For economical dosing of the disinfectant into the flow, we installed flow rate meters in the cleaning solution circuit, a disinfectant supply pipe and a dosing pump with an electric drive and a frequency converter. Thanks to this, the operator can quickly set the exact concentration of the disinfectant.
As a result, the liquid consumption was reduced and the high cleaning properties of the solution were maintained. The human factor was excluded during CIP cleaning.
Task 3. Ensure prompt change of equipment settings for high-quality preparation of cleaning solutions and disinfectant in automatic mode depending on the season
Depending on the season, the brewery produces different volumes of products, and also consumes different amounts of cold and hot water. To develop a solution, we needed to create two algorithms for preparing the CIP station for operation:
- during the summer period in time up to 20 minutes;
- during the winter — up to 40 minutes.
We have installed pressure sensors to control the liquid level in the tanks of cleaning solutions. To save water, a separate tank for recuperated water has been added, which is replenished during the last flush. This liquid is not drained into the sewer, but is used for the next wash in the first cycle of product residues cleaning .
We have installed a separate pipeline through which excess hot water during the high season is directed to fill vessels with hot cleaning solutions, as well as to equipment sterilization procedure.
As a result, we saved the manufacturer from having to fill the entire vessel. The CIP-station independently collects the required volume of cleaning solution in each case. All of the specified set of actions, combined with an optimally selected plate-type heat exchanger, made it possible to prepare the CIP station for operation within the time frame specified by the customer.
The performed work allowed us to solve another problem that the customer identified to us.
Task 4. Optimize the consumption of hot water for cleaning, taking into account seasonal prevalence
To save steam and hot water, we installed an additional recovery tank and developed two hot rinse programs.
- During the high season of beer production (with an excess of hot water), sterilization is carried out from the hot water ігзздн pipeline, without the use of additional steam.
- During the low demand season, the CIP station uses water from an additional tank for flushing in a closed loop circuit.
Task 5. Integrate into the equipment a modern cleaning parameters monitoring system
We left the customer with the QiVisor remote monitoring system, a technology that helped us collect the initial data for the design. At the same time, we provided personalized support 24/7.
QiVisor quickly captures any equipment failures and parameter changes. The system allows analyzing the history of cleanings performed for the past 12 months and generates a report with which you can optimize processes.
As a result, the customer's quality specialist and the technologist received a convenient and informative tool for remote monitoring, analysis and adjustment of such indicators as:
- frequency of cleanings;
- duration of cycles;
- temperature and concentration of solutions.
Task 6. Provide a possibility for further CIP station upgrades and enhancement with additional equipment
In technical requirements the customer indicated to envisage the expansion of the functionality of the CIP station in the future, for example, the installation of an additional circuit for cleaning new equipment.
We have selected vessels of the maximum possible volume in the given geometric parameters. 3D scanning was used to design in the conditions of existing premises.
With the expansion of functionality, the customer will be able to adjust the parameters of the solutions independently, taking into account the increased load due to a quick change in the settings of the CIP cleaning program.
The client received a reserve 30% of the free space in the electrical cabinet for the installation of additional equipment. The vessels have separate outlets (previously plugged) for connecting an additional circuit, which can be easily opened if necessary.
We also provided the customer with detailed assembly drawings. They were used during the installation phase, which the client's staff did in-house to reduce the cost of the project. And in the future, the drawings will help when installing additional equipment in the brewery.
Task 7. Ensure fully automatic operation of the CIP station
The customer separated the task of minimizing the impact of the human factor and switching to automatic mode all equipment cleaning processes, both the filling line and the tanks of the CIP station itself. Human errors lead to excessive energy consumption, equipment breakdowns, affect bacteriological purity and, as a result, the quality of beer.
We have used software that allows one brewery specialist to control the entire cleaning operation, adjust parameters and save on energy costs without compromising the quality of cleaning. The number of programs is not limited. Only the circuit for cleaning the tank of the CIP station is assembled by hand. Everything else works automatically.
As a result, the customer significantly reduced manual processes. In addition, he receives regular and operational analytics of the operation of the cleaning components and can optimize the operation of the SIP station due to the remote monitoring program from VIRAVIX.
Our client has a century and a half history of brewing, with its own traditions. But he also needed modern engineering solutions to reduce costs while maintaining product quality.
This project confirmed one more observation: there are no template solutions for breweries. An ordinary task can be difficult in practice due to local conditions.
Our engineers have benefited from their rich experience and knowledge of modern technologies in the food industry. And we like to solve non-standard tasks.
We are ready to help you effectively develop your business, enjoy work and high income!