by: Maria Buss and Nicole Johnson
With over three decades of expertise in bulk material handling, we understand the critical importance of sanitation in food processing operations. Ensuring both hygienic construction and effective cleaning methods is paramount in minimizing the risk of bacterial growth and foodborne illnesses caused by pathogens such as Salmonella and E. coli. The World Health Organization estimates that nearly 1 in 10 people globally fall sick each year from contaminated food, underscoring the need for rigorous sanitary practices. At HaF Equipment, we prioritize these principles, integrating Clean-in-Place (CIP) and Clean-out-of-Place (COP) systems into our machinery to provide comprehensive, efficient, and safe cleaning solutions that support the highest standards of hygiene in the industry. By leveraging these advanced systems in cleaning food processing equipment, we help our clients maintain optimal cleanliness, enhance operational efficiency, and ensure the safety and quality of their products.
Clean-in-Place (CIP) vs. Clean-out-of-Place (COP) Systems
At HaF Equipment, we prioritize systems that support CIP and COP cleaning techniques.
Clean-in-Place (CIP): These automated systems clean the internal surfaces of process equipment without disassembly. Clean-in-Place (CIP) systems offer an efficient solution for enhancing the sanitation process. By minimizing exposure to high temperatures and chemicals, they contribute to a safer workplace environment while also aiding in the effective management of water and chemical expenses. CIP is ideal for tanks, pipes, and pumps. When designing CIP systems, it is important to factor in additional components like extra ports, different gaskets, waterproof equipment, airlock dummy shafts, sprayballs, and wands to ensure thorough cleaning.
The benefits of CIP include:
- Reduced Labor Costs: Automating cleaning saves time and manpower compared to manual cleaning.
- Improved Safety: Eliminates the need for workers to handle harsh chemicals at high temperatures.
- Enhanced Cleaning Consistency: Automated systems deliver consistent cleaning results every cycle.
Clean-out-of-Place (COP): Equipment unsuitable for CIP cleaning, such as fittings, utensils, and tank vents, is cleaned in a COP system. These components are submerged in a tank containing a hot chemical solution and agitated for a deep clean. In the COP procedure, the immersion washer is crucial in effectively cleansing items. These elongated tanks utilize powerful jets of detergent solution to create agitation and remove residues from processed materials and ingredients while they are immersed in hot water. Subsequently, the components undergo a thorough sanitization process to ensure a deep clean. Once cleaned, the parts are reassembled and reintegrated into the manufacturing equipment. It is important to note, however, that prior to immersing equipment in a COP tank, heavily solid equipment must be pre-rinsed. Failure to do so may result in the chemical bath becoming overloaded with excess debris, leading to re-deposition on the cleaned equipment. Larger items that cannot be fully submerged in the tank may obstruct circulation ports, impeding turbulence and hindering the cleaning process. In such cases, manual cleaning is recommended. Smaller and more intricate equipment parts are better suited for COP systems as they are typically inaccessible through CIP procedures.
Key points about COP systems are:
- Effective for Complex Parts: Cleans intricate equipment parts that CIP systems may not reach.
- Manual Pre-Cleaning Necessary: Heavily soiled items require pre-rinsing before COP cleaning to prevent overloading the chemical bath.
- Visual Inspection Crucial: After cleaning, parts should be visually inspected or swabbed to verify cleanliness.
Choosing the Right Sanitary Design System
CIP and COP systems offer advantages, and the optimal choice depends on your specific needs. CIP systems generally require a higher initial investment but offer significant labor savings in the long run. The following table summarizes key differences:
|
Feature
|
CIP System
|
COP System
|
|---|---|---|
|
Cleaning Method
|
Automated
|
Immersion
|
|
Disassembly Required
|
No
|
Yes
|
|
Labor Intensity
|
Lower
|
Higher
|
|
Initial Investment
|
Higher
|
Lower
|
Comparing CIP and COP Systems
Equipment
Both CIP and COP systems require a range of equipment. These can include:
- Pumps
- Heat Exchangers
- Sensors (temperature, etc.)
- Tanks
- Flow Meter
- Strainer
- Dryer
- Sprayball
Shared Benefits and Cleaning Chemicals
Both CIP and COP systems:
- Enhance efficiency.
- Reduce cleaning time and cost.
- Improve the hygiene of equipment and manufacturing plants
- Increase the lifespan of the equipment.
- Are compliant with regulatory standards
- Exceeds regulatory standards with the capability of cleaning deep crevices that are often overlooked during manual cleaning.
Tip: Using both systems will drastically improve overall cleanliness, potentially allowing a facility to forgo manual cleaning altogether.
Both systems utilize similar cleaning chemicals, typically including:
- Caustic solution (breaks down bonds between contaminants and surfaces)
- Acidic solution (neutralizes the caustic solution and removes mineral deposits)
- Sanitizer/disinfectant (eliminates microorganisms)
The specific cleaning cycle steps will vary based on the equipment and product type.
A typical CIP cycle involves:
- Pre-rinse
- Wash
- Intermediate rinse
- Acid rinse
- Sanitize
- Final rinse
A typical COP cycle involves:
- Dry cleaning
- Rinse parts in the COP tank (with cool water under 80 degrees Fahrenheit)
- Clean the equipment with a soap or chemical
- Rinse the parts in the COP tank
- Complete a visual inspection or swabbing (ensures the parts were adequately cleaned)
- Sanitize the parts in the tank
Food manufacturers must invest in sanitary equipment design and implement effective cleaning procedures. By choosing systems that prioritize these elements, they can ensure a safe and hygienic production environment, safeguard their brand reputation, and promote consumer trust in their products.
ABOUT HaF
HaF Equipment offers turnkey services for projects big and small. Our team understands the concerns of our customers and takes the time to listen. We develop a plan and communicate along the way. If you need someone you can trust and want to eliminate the stress of managing all the details of your next project, HaF is Ready To Connect.
CONTACT US today to discuss your next project and how our team can help from concept to system solution.