 Good morning. My name is Jim Cousin, and I'm the vice president of content for the PMMI media group Publishers of packaging world health care packaging automation world and pro food world I'm also the publisher for OEM the official magazine of PMMI who produces the portfolio of pack expo shows in the US As well as pack expo pack Mexico Vegas is in September 23rd through 25th this fall All right the Center for Disease Control estimates that each year in the US 48 million people get sick from a foodborne illness 128,000 are serious enough to be hospitalized and 3,000 people die Researchers have identified more than 250 foodborne diseases Most of them are infectious caused by a variety of bacteria and viruses and parasites Harmful toxins and chemicals also can contaminate foods and cause foodborne illness For any CPG these types of incidents can be disastrous for the brand In this place, CIP is a widely utilized practice Especially for systems that process food dairy beverages and pet food But CIP is also employed for cosmetics and personal care products pharmaceuticals Nutraceuticals and biotech Well-designed CIP system can help meet the challenges of complying with the Food Safety Modernization Act FSMA outlines recommendations on cleaning and sanitation as well as sanitation preventive controls and verification This webinar is designed to help consumer packaged goods manufacturers understand and successfully use CIP systems Our guests today are Caitlin Lucia senior process engineer on the global engineering team for Campbell soup Caitlin has been a process engineer for Campbell's for the past six years and previously worked as a project engineer for Cargill Her focus has been an aseptic processing and cleaning of aseptic processing systems Brian Downer vice president of sales and marketing for Animatics began his career as a hygienic process system engineer over two decades ago He has designed and implemented processes and cleaning systems for a variety of beverage food and bio pharmaceutical companies Now let me turn it over to dr. Steven Perry one of the managing directors of PMMI's OpEx leadership network And I'd also like to say a special thanks to our sponsor Emerson for making today's webinar possible Dr. Perry Good morning everyone Jim. Thank you so much what I'd like to do is to Start off by talking a little bit about the purpose of today's webinar You can see on the slide. There are four key areas that we want to to cover today First there is an update on PMMI's OpEx leadership network, which I'll provide for you in just a moment Secondly, we want to give with our panel a sort of a general introduction to CIP and then a guidance Some guidance that's contained in the document for CIP and then give the audience time for a little bit of question and answers If we could get to our next slide We'll go to operational excellence in night in 2011 PMMI Developed the OpEx leadership network As you can see on the the next slide the operational excellent side operational excellence of bases based on a philosophy of leadership That derives the deliberate intentional and sustainable improvement of production operations and three key areas Focusing on the needs of the customer Secondly empowering employees and then optimizing processes The OpEx leadership network is a network Predominantly CPGs and PMMI members OEMs and suppliers To provide networking and tools to facilitate the communication between suppliers and end users Currently there are more than 250 companies that are collaborating on these documents And primarily the documents are designed to develop best practices and protocols And by the way, they are free for industry-wide adoption at the end of the Webinar today, we will provide the website the OpEx leadership network Org website where all of these Documents are available for free download So how does the OpEx leadership move from ideation to adoption? There is a clearly established process for Collaboration between CPGs and OEMs most often they The topics begin and develop out of PMMI forums That could be the top-to-top vision 2025 and the PAC Expo events and of course the online and Publications for the PMMI media group Those topics go to the OpEx executive council There are about 40 folks that serve CPGs that serve on that OpEx executive council The OpEx executive council takes the particular topics under advisement Develops a task force that task force in turn Determines whether there is a solutions group to be formed Once that solutions group is formed that group begins to get to work to develop that work product We then pilot those work products in factory in a factory or a facility for one of the CPGs And of course we take a look at the experience that has come from that the data the metrics that That spring from those pilots Analyze that and ultimately complete the document and get it out for industry-wide adoption So a solid ideation to adoption process To give you an idea of what this looks like These solutions by the way as I mentioned are developed by industry for industry These are not consulting groups or university programs. These are actual CPGs and OEMs Who are currently in industry? So all of these solutions are developed by practitioners in industry for the industry itself You can see from the wheel On the screen now there are three primary areas that we work in people and process and in projects and what you're seeing appearing on the screen now are the 20-plus documents work products that have been been produced By the OPEX leadership in each one of these areas workforce engagement and worker safety and the people area CIP that Jim just mentioned a moment ago that we're going to be Drilling down and of course is the purpose of the webinar today validation of the kill step and heat process low moisture foods of validation Documents and then on the products productivity side in process a couple of OEE Calculators and a remote access equipment document to help OEMs and suppliers access And help CPGs troubleshoot equipment remotely Also on the sustainability side discerned journey of sustainability as we move over into the projects side We have two of the most significant documents there and often downloaded documents on requests for proposals and how to conduct effective factory acceptance tests and Finally, perhaps the most frequently downloaded document in projects relates to total cost of ownership so that is what the portfolio of products and That's the OPEX leadership network has developed looks like and the focus of today's as I mentioned a moment ago Is this CIP document that you see on the screen now and by Way it is available for free download now to help us delve into this CIP document Let me introduce Again, Caitlin Lucia from Campbell's and Caitlin if you'd like go ahead and kick us off Thanks, Steve. So prior to this document, there wasn't a cross-industry document on CIP In our solutions group strove to provide definitions and actionable guidance that could be leveraged across food plants Several individuals were part of the creation of this document representing food manufacturers equipment manufacturers and consultant groups And this is the collection of those representatives That worked on this document We'll start with a couple of basic definitions to get everybody on the same page So cleaning is the process of removing soils. Your soil could be a Product it could be liquid solid particulate. It could be an allergen. You're worried about it could be build-up scales films You have several methods for cleaning to to use clean clean a place CIP, which is what we're going to talk about today Clean out of place Manual assisted and dry cleaning and the factors here. We're going to go through today for CIP There's a couple pictures for you of various cleaning methods Most of you should be familiar with with all of these cleaning clean out of place is removing the Components from the system and cleaning in a separate wash tank dry cleaning. It's just as it sounds vacuuming or brushes manual cleaning anything that's that's manual Sanitizing is the process of reducing the number of microorganisms present on a cleaning surface This is what we're not going to focus on today But we want to get it out there as a definition to be clear So why would you want to clean? There's several reasons to clean and not all of us are going to have the same reasons to clean it might be a Chemical reason allergens or gluins or you're removing chemicals from your process Might be foreign materials. It might be biological build-up pathogens or spoilage. It might be a requirement from Regulatory agency it might be to change between different products and maintain product sensory characteristics Or to be in compliance with label claims such as organic or kosher free of non-gmo And it also might be operational Maybe your heat exchanger doesn't work after 40 hours of processing and you need to clean it to remove the build-up Everyone's reason is going to be different When you are determining your cleaning approach, you're going to ask yourself a couple questions What do you want to accomplish cleaning cleaning and sanitizing? What are we trying to remove proteins allergens carbohydrates fats? What's the state of your solid viscous? Fowling scale and then what's your water chemistry? Do you want to use water alkali acid sanitizer? Do you need special additives and then once you answer all of those? You can decide how do you want to accomplish it with CIP and assisted cleaning clean out of place or manual? I'll hand it over to Brian Downer to get us through the five rules of CIP Thank You Caitlin. I appreciate it As Caitlin said, you know, there's a lot that goes into how we're going to clean One of the big things we just we looked at as a group in OPX is what are some basic rules we can give people and one of the first ones We we land it on is really there's five fundamental rules about clean in place. One is Obviously the system and the components in the system have to be designed for cleaning place Seems simple, but it's as we'll go through it can be one of the more fundamental mistakes people make from time to time Second it has to be installed to be cleaned in place again when it said it sounds like Something that wouldn't be a concern But time and time again we find that the implementation the installation of these systems is a culprit that allows it not to be cleaned in place Active monitoring and adjustment just like anything you want to be sure it's doing what you originally designed it to do So we're going to go through some of the criteria there that are common in the industry Recording and verification. This is a big one Really has become a Topic of conversation after the Food Safety Modernization Act This is where the regulators are looking for Did your system clean the way you said it was going to clean and can you verify that that is the proper way to clean it? So again, something we'll look at here in more detail And last and certainly not least is preventing maintenance and calibration. And again, this is Keeping the system operating the way it was designed the way it was installed to work So that you know that on day one or day 1,000 it is operating in the same method same mannerisms same functionality so Go to the next slide. We'll talk about designing for CIP so This can be a selection of equipment to be cleaned in place one of the fallacies that many people Fall under is is that if a piece of equipment is designed for a food process or even a pharmaceutical process That it is designed to be cleaned in place and that is not true Actually any good example is the picture at the bottom there of that that pump That pump is a 3a certified pump It is 3a certified for clean out of place and if you're not familiar 3a 3a is an organization in the United States That works directly with the government. They're part of the Organization that sets standards for the design of equipment for food production So that is a good great example of a pump that is designed to be for food It's designed to be used in a food process. It's designed to be cleaned but not to be cleaned in place The other picture there is a valve again We're showing the cross-section of this valve It has areas where soils can deposit and can be difficult to be cleaned out That would be an example of something that would not be designed to be cleaned in place Even regardless of its type of operation. It would not clean without being taken apart by its sheer design one of the other organizations besides 3a that helps in this is EHE-DG the European Hygienic Engineering Design Group. You'll see the logo there at the bottom They are a Organization that harmonizes with 3a they stand the guidelines and standards are not the same But e-hedges use a lot in Europe where as 3a is the primary guideline here in the United States so Installing if I look at the next slide And we think about how we install this equipment so you select the proper equipment You have engineered it to be positioned properly to drain properly you've got the proper line sizes Everything the engineering is complete and done properly. However The way things are installed can matter Significantly so if we take a look at a couple of pictures here We have the first picture that shows a valve and there's a red arrow That's a dead leg that area will collect product materials It will never clean. There are guidelines in both the 3a and the e-hedge Documents that talk about this but that is an example of you know, even if those valves were to be Clean able to be clean in place the way that's installed that never would it would be a Bacterial problem regardless of how good your CIP system is designed The second picture is an example of a welt It may be difficult to see but from the outside that tubing weld looks fine You know unless you've been a weld inspector for many years you may not suspect there's a problem But if you looked at the inside closely, you would see that it's actually not welded on the inside There's a significant crevice and a crack Would be a major Bacterial concern it would never clean And it could certainly cause product integrity or you know, even health risk issues over time So a craftsmanship the way the systems are laid out and designed. Are they drainable? Do you have the proper slope? If you have a long run of line many times people don't like to add slope because it is inconvenient But it is a necessity. So again making sure that You're reading these guidelines for the installation the proper installation of this equipment that is being done properly that you're hiring trained Contractors who are familiar with this not just with welding materials, but with installing sanitary systems is is very important So moving to the next slide Discussing active monitoring You have a system in place Process system is designed to be clean in place. It's been installed properly. Everything drains All you need to do is provide it with the right amount of chemicals and at the right temperatures and flows Everything is going to clean properly then and that's great and on day one when everything works. That's fantastic But making sure that you're monitoring this that you're maintaining the proper flow If we look at this flow diagram shown here on this slide, you'll see obviously we have a pump there at the bottom It's there's a strainer and a flow meter the flow meter is controlling the pump If you look at that way that loop is work that works what we do there is we have a set point We say we have to flow at a certain flow rate for this entire circuit for it to clean properly We've documented that through our Verification and the flow meter Makes that happen makes the pump run at a certain speed so that we have the right flow same thing with the temperature We have a heat exchanger shown there in the next That's a steam to water heat exchanger and there's a control loop with the temperature transmitter so that we are Sure that we are consistently providing the right temperature Not only throughout the cycle, but from one cycle to the next cycle from one week to the next week Maintaining a consistent flow temperature and chemical concentration is very important Sometimes these things are done manually somebody goes and titrates chemical throughout the run. It's not a It's not a practice that typically is recommended because it requires human interaction and mistakes can be made and there's no way of Tracing or recording those things if you don't have electronic Means which again is very important when we talk about Regular regulators and how they are monitoring your systems to be sure you're doing that properly So not only being able to maintain throughout but also being able to verify that What you've done has been Is the correct thing to do so recording and verification, you know, we have Examples here showing, you know, our first example is what's called a riboflavin test. This is done extensively in the pharmaceutical Market and we see it more and more in food This is an example of very making sure a spray device inside of a tank is actually cleaning the tank properly It's not a complicated test It can be done. There's many people who provide this service in the field and it allows you a good verification that you have the proper spray device sometimes it can be Misunderstood that you know a spray device and a tank Equals a clean tank and it really does and it has to be the proper device has to be designed not only for the tank specifically but also for the soils you're planning to put in there and it's always a Suggestion on from my standpoint that we should verify these things On the bottom there you see a picture of a swab test. This is Something that should be done consistently and periodically Many customers do this after every cleaning in certain spots just to make sure this is being cleaned the same every single time and You know these verifications that things are being cleaned are a way for us to know that our protocols You know those times the temperatures The concentrations of chemical are accurate or are suitable, but we also have to record that We're doing that that same way every time and that's where electronic recording or you know some sort of a a Trace paper trail that of what we've done every time has done the same way Every single time because if we verify that it works this way, we have to prove we've done it that way every time Now we Have to do that in doing that We have to be sure that the system operates the way it was intended to operate so if Mainly if we're not maintaining the system properly not only the CIP system, but even our process system You know an example here is instrument calibration if we're relying on the instrument to tell us what the flow rate is to tell us What the chemical concentration is we also need to be sure that we're calibrating those instruments on a regular basis So the instrument is reading properly In certain circumstances people even use redundant instruments where it's critical so one instrument is always verifying the other and if they Very too far from from one another. There's an alarm that goes off and you know you have an instrument out of calibration Strainers simple and something as simple as inspecting strainers, but you know, it's important to have a strainer on your CIP system You're cleaning you're going to pick up Debris sometimes that debris can be Undissolved product ingredients sometimes can be foreign objects pieces of plastic or metal So you want to be sure you have something to capture that so strainers a great way of doing that making sure you have a regular process for checking those Ornalastomers is an area that many people I will fail to to think about but you know a gasket between a fitting in your process system or in your CIP system has a reasonably short life Shorter than most people think a lot of times people will not replace an elastomer until they actually see a physical leak Well, once you actually have a physical leak of an elastomer many times That means that elastomer actually has been failing from a cleaning standpoint for a long time Even before it failed from a seal standpoint as a mechanical seal so we see many people have a Regiment where they go through and they change their seals Before they have a failure just like they would change a pumper of valve seal. They'll change your triclamp seals On a regular basis and maybe every few months every year Same thing's true with pumper valve seals as I mentioned. Those are also those where Once you've actually had a mechanical failure You probably have been having a sanitary failure for some Significant period of time prior to that so changing those things on a regular bait and Regular preventative maintenance schedule is important not only from an operational standpoint, but also from a sanitary sanitation standpoint Next slide, please so designing for CIP Effective cleaning really boils down to these six factors and I like to start with time on the Lower right there because time is the one thing that seems everybody wants to reduce There's as much time as we have in the day. There's never enough time It seems like to get these operations done the way we like to get them done So we start with time anything any other factor you see there is going to help you reduce time or Unfortunately, if not done properly They can also increase the time because that tends to be the fallback when something doesn't get cleaned right We spend more time doing it. The whole purpose of a clean-and-place system really is time efficiency You are saving time because you're not taking the system apart and cleaning it by hand We hopefully are pushing a button and the system goes into a cleaning mode. So in the essence of saving time the first really is temperature and Temperature is critical But it also has a diminishing point of return. In fact, you know, it's important to Match your temperature to your soils as Caitlin mentioned earlier. We have different soils. We're going to be cleaning They can be fast. It could be oils. It could be proteins It could be minerals. So you have to identify those and Then make sure you match a chemical to those and then match your temperature to your chemical for instance, there are certain cleaning chemicals that will actually foam if they are below the temperature of say 125 degrees Fahrenheit and the foaming can actually Cause additional problems. Well, it's not cleaning and it certainly will increase your time to clean So making sure you have the right temperature As well, although temperature is important It can certainly help and speed up the cleaning too much temperature Can be a detriment you can actually have Situations where you will denate your proteins and actually cause the system to be more difficult to clean if you overshoot a temperature So correct and consistent temperatures are very important and it's not always the more the better in that case Same really is true for chemical concentration. If we move our way around The chemical concentration once you selected the right chemical Making sure that you use the right amount too little obviously is is no good. You're going to have Take longer time the chemical over time as it reacts with your Product it's going to de diminish in its concentration So you want to have a system where you're constantly Maintaining that concentration if you're doing it manually by having somebody, you know, physically check or to hydrate the chemical over period of the circuit or the CIP cleaning circuit that can be time consuming as well You have high and lows and you can have the tendency in those cases to overshoot the chemical which can also be a Problem too much chemical for one it can be a waste of chemical, but it can actually create Situations where you can harm your equipment it can too high chemical concentrations can destroy elastomers It actually in certain cases they can actually even destroy the metal the stand the stainless steel So you want to be sure that you have the the proper chemical concentration And that you know what that is and working with your soils that you're trying to clean and your chemical supplier to find that Right chemical concentration and then keep it consistent pressure Many times people don't appreciate, you know, they think well, I have the right flow rate I don't really need pressure but pressure can be a great indicator Particularly when you're using certain devices like a tank cleaning device that requires a Significent a certain pressure to operate properly many almost all tank clean devices operate based on a flow and a pressure And so monitoring that pressure particularly when you're serve Sending CIP solution to a tank clean device is an important measure and one I recommend At particularly as you get into more sophisticated tank cleaning devices So good example of where pressure monitoring can be important Turbulent flow or mechanical action. This is our flow our flow rate There's a given flow rate for Every size process line We use a general rule of five feet per second as a velocity and Many we we use that rule because we know that cleans the branches of teas and some other Standard components well Occasionally people will move that flow rate up and there's evidence to show that six or even seven feet per second can Speed up the cleaning process not as a linear relationship, but it it does help There is a diminish important return with with that flow rate as well So, you know going to 10 and 12 doesn't necessarily hasn't been shown to necessarily help As some people might think it would there's but having the right amount of flow is important and the Critical thing here is is to be sure you have the right amount of flow for the dissent the Equipment you're designing and plan to clean so Looking at the equipment itself the flow connectivity and temperature measurement Here's a good example of how that works return controls cleaning duration is recorded on your cleaning You've got fluid properties Feedback on your heat heat transfer so that you have control of your heat you have control of You're courting that as well. This is a good example here of a single tanks Supply see a piece of pie system. So it's important to have the monitoring in the proper place in here We are making sure that what it you know having those controls on the return side that everything that In the circuit has seen the least or the coldest Material so we're not Hoping that everything that we goes out comes back the same way so Good example of having equipment placed in the right spot. So I mentioned before Single-tank single-use system different types of CIP equipment you would have Single-tank systems are great. They're they're small. They're flexible You know, you can use different types of detergents and concentrations if you've got a small system To clean or if you have an allergen concern single-tank systems are Good good opportunity or good piece of equipment to use Disadvantages really they use significant amount more water and more chemical And there is a significant time delay to reach temperature as well as to change and dump in between cycles So it certainly is takes longer if you're using a single-tank system Whereas our next slide shows a two-tank system So versus a single-tank system looking at a multi-tank system Or what's sometimes referred to as a reuse CIP. We have multiple tanks where we can store detergent Or acid product solutions from one cycle to the next this allows us basically to reuse A lot of the energy a lot of the chemicals. We're not dumping that down in the drain This is what we see most commonly in the food industry Obviously lower cost of chemical and water usage. We have faster heat up times because we've already Gotten these systems up to temperature and each step our rinse our wash etc. Have their own dedicated tank where those solutions are coming from them so Typically very common for what we see in the food industry is a multi-tank system like this we look at Moving to the next slide some considerations when we're looking at sizing the CIP system so the wash tank size is Important it's not terribly complex, but it can be trickier than some people think about how so we've given some examples here of how you would size a wash tank and Important to work with your suppliers who's supplying this for you They can oftentimes can help you figure out, but it does need to be designed for your circuit a generic size wash tank might work, but It could cause you more problems than sizing it properly same things true with a rinse tank Important thing for a rinse tank that it's oversized to recover the increased volume of rinse water because as you rinse you Oftentimes you're going to be adding makeup water So again important to work with your vendors to be sure you're sizing this properly a Question that comes often is about heat exchanger sizing general rule thumb opx group Uses is a 30 degree Fahrenheit rise per pass so every time the water moves through the heat exchanger It is gaining roughly 30 degrees Fahrenheit Reason for this you have heat losses as you're cleaning so you need to make up those heat losses. You also have some Fresh water being added in which will be coming in cool And so you have multiple areas where you're going to be losing heat need to regain it You don't want to gain heat too fast because you can actually have thermal shock So one of the concerns at times has been that you know maddening too much heat and the system can actually be Shocked by that so again good rule thumbs 30 degrees per pass moving on Piping so flow rate through piping I mentioned earlier rule from 5p per second of Getting proper flow through any size any pipeline size here. We show that as a three inch Line is 102 GPM a four inch line is nearly 200 GPM. So we get into very Significant flow rates as you try and maintain that if you choose to go to a higher flow rate Again, even more even more flow required so you can see that the demands on the CAP system can be great the design itself You know free draining slope to drain we show here eccentric reducers Very important to use those particularly in horizontal lines dead legs T short outlet teas are very important There's guidelines for what those dead legs should be but Anywhere you have a spot if you don't know what a dead leg is It's basically a spot where flow cannot go from in one end and out the other so The branch of a tee or the side of a tee that has a pressure gauge or something like that flow can go in But it has to stop and turn back and go the other direction So those are dead legs can be very difficult to clean important to make those as short as possible Make sure your last moisture compatible of course and Separating always separating production from CIP solution and it's important to have that separation by more than just a valve seat One single valve seat if it leaks which they can do Is going to put CIP solution in your product and we don't want that so important to have clean breaks or double-block and bleed or mix-proof Functionality somewhere in your piping design Valves and piping circuits, you know be sure you pulse your valves a valve seat needs to be cleaned It has to be lifted for that to be cleaned. There are cavities in those valves that need to be cleaned by pulsing the valves It's good important to close against the flow particularly with the stem type valve because you otherwise you get hydraulic shock and Then sequence pumps and valves to avoid hydraulic shock again. This is where you consult your engineers tank nozzles The tank nozzles the ports and the tanks manways Those are the most difficult areas to clean in the in the vessel Try and keep those as few and as short as possible Are important as well as keep the diameter of those ports small a large report is easier to clean It's easier to get solution sprayed into it spray devices Uniform coverage obviously is important sometimes if you have certain types of product that Saturation from the outside is not going to clean it You need to actually penetrate through the crust of the product You might want to look at different types of jetted spray cleaners like we show in the picture on the far right there in the tank and then CIP return pumps the CIP return pump is Always going to be designed so that it is being starved flow. It should be flowing greater It's a capacity for the return pump should always be greater than the capacity for the supply coming into it This way we never build up what we call a bath ring or bathtub ring in the bottom of the tank As soon as water falls through the bottom of the tank and into the return pump. It's pulled away. So Again just small but important so designing a system Next slide so as we look at controls and automation You know It's a these systems that we've talked about They do need to have Automation component to them, you know the flow rate the concentrations Even the recording, you know is highly suggested that to be automated the computer takes care of this remove that human interaction remove that human error One of the biggest things to consider on your controls and automation is that you have proper security levels, you know, it's Controls is not a it's not a new thing to food plants by any means not a new thing for cleaning I've been using it been using automation and in cleaning for decades But as these systems get more sophisticated they get easier to use they also get easier for people to get into and Change things it shouldn't be changed and your cleaning system. It's a recipe. It needs to have integrity So making sure you have proper lockout is is critical in that case At this point I'd like to pass it over to to Caitlin again to talk a little bit about the documentation of all these Aspects that we've discussed so far. So Caitlin Thanks, Brian. So as Brian talked about before documenting your process and Recording your flow concentration and temperature versus time for your CIP is important to prove That you did what you said you were going to do and then it also alerted you to any problems that you had doing your cycle Without having someone stand there to watch it to take two minutes longer than it usually does does it take a little bit longer to get Up to concentration is your flow a little bit less than it used to be but still above your minimum So as well as keeping the regulators happy it also helps you troubleshoot later If you keep an accurate document of how the CIP cycle went it depends on your industry and in your plant how old it is whether or not you have a Fancy electronic recorder like the one shown here or you have something simpler like a paper chart recorder But both would be adequate to to cover your documentation needs Next slide We're gonna go through us a short example CIP process And I want to heavily stress example Everybody's process will be different depending on the soils that they're trying to remove or the environment in which they are Operating so this is purely for example purposes One or more of these steps might be added or removed depending on the particular application So every every cycle kind of starts in this this way with preparation once you come out of production You get to prepare your system a pre-rinse I'm your wash cycle or cycles another rinse and then a sanitizing That would be the optional one for a lot of industries and then a final rinse and back into production Next slide, please So preparation often overlooked but very important When you're going in from production into CIP you want to get rid of as much product as possible From the the the system It only takes longer if you leave a lot of product in there to do your CIP and in this step You'll also be changing any positions on swing panels or removing any components that have to be cleaned out of place Making sure you have enough chemical when whatever other pre-start checks you have to do The pre-rinse removes the gross residual product soil from your system before you start introducing chemicals you can use different Technologies to determine your rinse length. You can use turbidity pH conductivity And then you can reuse the recovered rinse water for pre-rinse if that works for your process Next For washes typically in the food industry we use it alkaline wash or caustic wash It's most effective for Proteinaceous and organic soils and your temperature and concentration that you pick would be based on your soil load and your Particular soil after your alkaline wash you're going to go into an intermediate rinse and To separate your caustic from your acid and you can measure your effective rinse with kind of connectivity or pH an Acid wash is usually used to remove the mineral deposits And a note of caution not to go crazy as Brian talked before because overdosing can damage your 300 series stainless steel Which would not be great? Final rinse you want to remove your acid from your system and avoid Sending any into your product on your next step and you can measure that with connectivity or pH as well and Then for some industries sanitation is included in the CIP process This would ensure destruction of pathogens micro you can use thermal or chemical means and Depending on what means you're using you may or may not require a rinse following sanitation Sanitization sorry So here's a typical cycle or a fake chart that I drew up to show you each one and what it would look like The first here is the pre-rinse. So you're at a zero connectivity. You're a slightly warm temperature pre-rinsing your system Next it goes into a caustic cycle or alkaline cycle Keep going next slide So you'll see your concentration and increasing and your temperature increasing as well on the intermediate rinse You're keeping your system warm So you don't cool down and take forever to heat back up again, and you'll rinse back to a zero concentration On the next you'll go to your acid wash Where you see an increased concentration and increased temperature as well and then finally Your final rinse you're bringing it back down to a zero concentration and you're bringing it back down to a cool temperature you see the the flow pulsing back and forth and that is That's the pulsing that Brian talked about before to make sure you're cleaning your valve seats without hammering your system to pieces So then validation and verification For validation anytime you have a new system or you're modified the system or you're bringing in a new product or new soil You want to challenge the system to make sure that both the controls are set up The recipe is set up correctly and then you're getting the cleaning efficacy that you want You're at the end of running a sample cycle. You'll choose some parameters and run it You'll do a visual inspection Maybe an ATP swab or a micro test and you'll do it multiple times Make sure you get the same results if you pass those those results and then that's your validated CIP process for that system And for that soil If you were to change something later or add something later You would do it all over again and that gives you your validated CIP Then on an ongoing basis you want to do verification that your validated CIP process is still effective Brian also talked about this of doing a visual inspection doing swabs periodically either after every run or once a month or whatever frequency Make sense for your application You might titrate your chemical solutions or titrate your rinse water. Make sure you're an effective rinse I'm gonna throw it back to Brian to wrap us up Thank you, Caitlin. I appreciate it. So Again, you know, we started this off saying there were five basic rules We want to design for CIP use the proper equipment. We want to install that equipment properly and We want to actively monitor and adjust make adjustments record and verify and Then maintain and calibrate. So I hope we've Given you some examples here of how you do that. Maybe you raised more questions and answers that happen sometimes but if we move on to the next slide and We'll pass this over back over to mr. Perry Next slide please Thank you, Caitlin and Brian now each speaker has prepared some frequently asked questions We're gonna run through those for you now and if you have additional questions Please contact the speakers at the email addresses that you see on your screen So the first question is for Caitlin. How do I know what chemicals and concentrations to use for my process? Sure, so I won't be able to give you a fantastic answer because it depends It depends on your product your soil What kind of degradation you're seeing but Most likely Your chemical supplier if you send them your product or describe your soil, they'll be able to recommend a given chemical or selection of chemicals and do cleaning efficacy testing on your soil and They'll give you a guidance for temperature as well to run those out Very good at Brian, how do I know how long to make my cleaning cycles and at what temperatures? Well, I love like Caitlin has mentioned. It's really predicated on your soil The product you are using one of the things we didn't address earlier is even your water quality It's important to make sure your water hardness isn't affecting the efficacy of the chemical And that's that's something you work for your company on but the length of time is really going to be a matter of the Effectiveness that you've done through your verification process your ATP swabs etc. If it's not adequate you run it for more time You can also adjust You know temperatures as well Oftentimes that's going to be predicated again by your chemicals, but again check verify adjust Until you get the the results you're looking for Very good Caitlin, how do I retrofit my process systems for CIP? Sure, so since I is designing for CIP we we hit on several times as key for having a CIP able system You can't often snap your fingers to retrofit it You can start with the available standards and audit your existing process against those Are the components CIP able do I have the right installation like Brian went through for dead legs and Good welds and then Start tackling them one by one until you have something that would have been what you would have designed if you were starting out fresh You can also do the the riboflade testing to check your vessels as well If there's those that weren't designed for CIP in the beginning Very good Brian, can I recirculate rinses to conserve water? That's a good question Do get asked that quite a bit the Interesting thing in the food industry. It's typically not been done, but it actually is done in the pharmaceutical industry It is not as easy as it sounds you can't do it effectively with a standard CIP system But there are ways to do it and in some cases there's a need Need for that, but yeah, it can be done. There's no regulation. It says that you cannot But it's a general rule of thumb people typically don't in the food industry All right, Caitlin. How do I make my CIP process shorter faster? You know finding efficiencies? It's the hundred dollar question is it? Brian also touched on this one before in our presentation. You're going to use your flow temperature concentration or your particular chemical as levers to decrease your time obviously within Constraints and you can also look at your prep step. Are you leaving too much gross containment in your system that? Makes the CIP take longer and would it be worthwhile to? remove more of that and recovery systems or air blows or some other Removal of your gross containment before you begin CIP to shorten your overall time Okay, all right, and Brian back to you What can I do if I don't have the drain capacity to handle the waste flow from a CIP system? so one of the things we didn't address and Is waste capacity of a facility, you know, it's not only do the floor drains handle the The effluent you'll be dispensing in a rinse because that rents as we talked about you know If you're a three inch line, it's 102 GPM your rents needs to be at that flow rate You could have a hundred or even 200 gallons per minute of water go into your drain So not only does your waste system? Need to be sized to be able to handle the chemicals or the potential solids that are coming to it But can the drains handle it and if it's a temperature or they designed to handle the temperature? So those are it's an infrastructure question if There are things that can be done That can be designed into the system to allow for smaller drains. There's opportunities retrofit where you can add Reservoir tanks that handle that effluent and hold it and then basically disperse it at a flow or flow rates you can use recirculated systems that are Allow that flow to go out at a lower flow rate than what the demand for the clean is but yeah There are there are ways to go about that but it's an important aspect to to be thinking about in your infrastructure our four drains and Very yeah, very interesting. So Caitlin if you want to swap out my single tank system with a multi tank reuse system What do I need to consider or maybe watch out for some pitfalls? Sure, the biggest Two obvious ones are space and cost You have to justify your your multi tank system and you got to find a home for it Then after that you want to look at allergens Or is it is it possible for you to cross or reuse your fluids? And then and one thing that people don't usually think about is because you're reusing your Your fluids you're gonna end up with some soil back in your CIP system And so you have to come up with a way to periodically clean your CIP tanks as well So they don't have build-up in them Those are the big three I would think for swapping out from a one tank to a multi tank Very good, Brian. How do I know if I need a 3a compliance CIP system and what are the benefits to the organization? So as I mentioned before for those who are listening or are familiar 3a it is a guideline that's used in the United States. It's actually The FDA and the USDA are part of writing these. It's actually a standard an antsy standard now In the dairy industry, it's highly used the regulators typically will be the ones telling people you need to have this 3a certified Or I highly suggest that it be 3a certified but oftentimes it's used in other food industries as a As a method for assuring that the system has been designed to be Sanitary and clean and as cleanable as I Guess the highest cleanability level and that's really what that does for you Is if if your regulator is not requiring it? But you want to assure that you have a system that has been designed at the highest level of hygiene for food 3a is a good way of Complying with that the benefit obviously is the assurance that it has it is meeting design and functionality you know a standard because that is the the ex de facto standard here in the US All right, and Brian again, do I need electronic record keeping of my cleaning process? So as Caitlyn mentioned before, you know a chart recorder charts from a chart recorder a paper Record are perfectly adequate and meet the requirements of the code of federal regulations There is significant Benefit to electronic record keeping and we're seeing more and more people that post both in On-site and cloud-based systems the advantages is that that record is easily accessible It's you know, you don't have to worry about well, where do we put that chart to get wet you know, did we misplace it and Multiple people within the organization can monitor those things. So no you don't have to have electronic record keeping But we're seeing more and more people move that direction because the technology is just there to do it Caitlyn how about Campbell soup do you have electronic and paper? Yeah depends on on the particular system or or age of the equipment and building but As long as it complies we we have we have things to support it So finally up for both of our guests, how do you go to management and justify the investment? In a centralized CIP system Caitlyn. Let's start with you. Is there any kind of argument from the? You know people allocating funds that you need this and you got to comply Sure, but I mean the biggest thing is time really Brian touch us before that that's really what turns your ROI over Is that essential I see IP system? if properly designed and Installed can can really cut down on the time that you're cleaning and that that allows for more time for production And it's fairly easy to use that as justification Or at least financial justification Exactly and Brian any tips from from from your end it's animatic Yeah, time is you know more time for production. That's the big one. We see More more people actually Doing it for labor savings, you know, they're just not able to find the labor maybe to do some of their more manual processes, so they want to do the labor savings and You know reducing the human interaction reduce reduces the risk So there's the risk factor as well, but time's usually the big big one if you're moving to a to a centralized Well, I want to thank you both very much for joining us here today and Stephen Perry where can people find out more about op-ex and upcoming webinars? Well, Jim, thank you so much Caitlyn and Brian. Let me thank you for an outstanding presentation this morning and Jim thanks to you for moderating us through this session With this CIP Webinar this presentation you all have had a chance to see firsthand The breadth and depth and quality of these by industry for industry work products Produced by the op-ex leadership network This CIP document as you can see on the screen along with all the others that I shared with you earlier this morning are all available At the op-ex leadership network.org you see the address there on the slide You go to that site you can see all of the documents there and again once again, they're all available for free download So guys in conclusion this morning on behalf of PMMI and PMMI media group and the op-ex leadership network We'd certainly like to thank our speakers this morning and we'd like to thank all the participants The listeners this morning for participating with us on the webinar. Thank you so much and have a good day