ZHONGRU 25-11-2016

An Automatic Clean-In-Place System


Automatic CIP system is an automatic and reproducible technology that delivers reliable cleaning solutions for various process equipments and piping, thus offering a significant advantage to pharmaceuticals and healthcare manufacturing companies. A processing system involves tanks, pumps, valves, filters, heat exchange units and process piping. This automatic technique has the ability to clean all these systems without having to dissemble their parts. This further provides cost-effective and regulatory compliant cleaning solutions.

Cleaning and maintenance of systems increases their efficiency, improves safety, avoids cross contamination and ultimately provides higher assurance to product quality. However, to achieve all these benefits, strong measurement and control of the CIP process is required. Pharmaceutical manufacturing plants should have specialties to determine appropriate amount of cleaning solutions to be used and be able to assure that all cleaning solutions have been removed from the systems before the next processing. They can use conductivity analysis to confirm cleaning processes.

Efficiently working CIP systems have some key objectives such as maximize safety to avoid cross contamination, minimize cleaning time to reduce impact on plant production and optimize thermal efficiency to avoid unnecessary heat loss and reduce energy requirements. Single-use and multi-tank are the two most common configurations of such system, employed in pharmaceutical plants. The tanks are drained between the programs to minimize the potential for cross-contamination.

The cleaning process involves a series of cycles including an initial and final drain step, a pre-rinse, a sodium hydroxide wash and a post-rinse. The time period of all these cycles vary from each other. Some of these cycles are sanitize in nature and reduce the level of bacterial contamination using strong oxidants such as hydrogen peroxide, ozone and other chlorine based compounds.

At the initiation of cleaning process, pre-rinse water is send through the circuit towards the product and a timing sequence based on flow rates and distances, switches the valves at the proper time to minimize the interface between product and rinse water. This process removes around 90% of product residue and reduces the total amount of washing chemical.