30 Route 18 | Suite 1 | Old Bridge NJ 08857 | Tel: 732-679-2200
INSIGHTS IN AUTOMATION
CIP Upgrade = Increased Sales
We recently worked with a client in the food and beverage business who wanted to upgrade their CIP [Clean in Place] system. In order to continue to meet FDA guidelines they also wanted us to fully document the upgraded system. The FDA expects firms to have written procedures detailing the cleaning processes used for various pieces of equipment.
Our client purchased a pre-owned CIP skid system with 3 tanks [for caustic cleaner, acid cleaner and water] which came with a Wonderware HMI and an Allen-Bradley ControlLogix PLC. The goal was to integrate the skid into a re-circulating closed CIP system which used an Automation Direct PLC for recipe management. The CIP system pipes water and a cleaning solution to over 16 mixers, bulk tanks, holding tanks and kettles. Our client’s typical CIP recipe involves multiple washes with water, rinses with cleaning agent and then washes with water, often followed by an air blow dry. The water and cleaning solutions are themselves cleaned and recycled as part of the CIP system.
Our engineering staff worked with our client to track and identify all system process equipment and instrumentation in order to produce piping and instrumentation diagrams/drawings (P&ID’s). As the scope of our client’s upgrade plans changed and grew during the time of our project, the P&ID’s ensured accuracy in the maintenance and modification of the CIP process.
Our engineers reprogrammed the CIP skid’s ControlLogix PLC to automate multiple CIP recipes. Networks in the system now include:
• Newly added Allen-Bradley remote I/O communicating via Ethernet I/P.
• Communications between the ControlLogix and Automation Direct PLCs via Modbus.
• Communications between the ControlLogix PLC and the Wonderware node via Ethernet.
Our client’s CIP system and the recipes are fully documented, with Standard Operating Procedures (SOP's) detailing their cleaning processes.
In addition the CIP system is completely automated, running predefined recipes. The HMI provides the operator with status messages. Cleaning cycles can be stopped and started manually. In the situation of a priority alarm, the cycle will automatically stop and can be resumed manually after the alarm conditions are cleared.
During our project, our client found additional reasons for expansion and increased the scope of the CIP reach as well as the creation of a clean room. They marketed their upgraded CIP system to existing and prospective clients and brought in new business through an expanded FDA-sensitive client base. In addition our client’s improved CIP system decreased costs and improved efficiencies. The CIP system runs better and can accommodate current and future growth. Final results?
• Opened new markets
• Increased sales through expansion of their customer base
• Set up data logging for report generation
• Added safety interlocks including stop functionality, alarming and warning systems
Want to know if a documented CIP system could drive your business growth? Give us a call at 732-679-2200 to discuss how we can help you with Control and Automation Solutions.