(16 Vessels!) =
One of our food and beverage clients wanted to:
Install a Clean in Place [CIP] system for 16 Vessels
Meet FDA guidelines by fully documenting the new system
The FDA expects firms to have written standard operating procedures (SOP's) detailing the cleaning processes used for various pieces of equipment.
Our client purchased a “pre-owned” CIP skid system with three tanks [for caustic cleaner, acid cleaner and water] that 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 that used an Automation Direct PLC for recipe management.
The CIP system pipes water and a cleaning solution to 16 vessels, including 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&IDs). As sometimes happens, the scope of our client’s plans changed and grew during the time of this project. Our client decided to not only increase the scope of the CIP processes but also to create a clean room. The P&IDs ensured accuracy during the installation of these modifications as well as in the maintenance of the CIP process.
Our engineers reprogrammed the CIP skid’s ControlLogix PLC to automate multiple predefined CIP recipes. We installed new communications networks for the system:
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.
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.
Full documentation with written SOPs provide the details of their cleaning processes.
Our client marketed their new CIP system and clean room to existing and prospective clients. This brought in new business through an expanded FDA-sensitive client base. In addition, our client’s new CIP system decreased maintenance costs and improved efficiencies. The CIP system can accommodate current and future growth.
Results for our client from a new documented CIP system and clean room?
Opened new markets and 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 or email us using this button.