BEVERAGE CIP USING ANOLYTE

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Beverage Clean in Place (CIP) Using Anolyte and the Aquadron

The Aquadron system is used at 50+ bottling lines to provide improved hygiene, faster CIP cycles and reduced chemical costs.  Below we discuss the specific issues relating to CIP.
CIP in beverage production

Clean-in-place (CIP) is a method of cleaning the inside surfaces of pipes, tanks and fittings without disassembling them. It is essential in maintaining hygiene in beverage production processes. CIP is also undertaken to maintain hygiene within bottling filler cabinet surfaces and on bottle filler mechanisms.

The CIP process removes material from the inside of vessels and leaves them in a clean and sanitized condition that will not contaminate future process runs. The CIP process allows regular high-quality cleaning without requiring breakdown of the plant and thus allows high-hygiene standards to be achieved. This ensures product condition and enhances shelf life.

At Aquadron we often recommend that clients think of the CIP process as two distinct phases -

CIP – clean in place - which is the action of cleaning the pipes to remove physical product and product residues.

DIP - disinfect in place - to sanitize the product-free surfaces and ensure that the equipment is not a source of microbial contamination for future production.

CIP cycles are undertaken to a) remove large volumes of product from the process line, and b) to clean the interior surfaces and remove small adhered particulate matter. Whereas DIP cycles are undertaken as a terminal disinfection, to disinfect the surfaces to ensure that bacterial and fungal cultures cannot colonize the area in advance of the next process run.

CIP / DIP cycles usually consist of a number of stages, that vary in type and length based on the product that has been / is going to be run through the system.

CIP cycles can range from a simple water flush at low-risk sites, such as mineral water plants through to cyclic caustic, acid and heat cycles with disinfection undertaken by heat or chemical methods at higher–risk sites such as dairy, beer and juice production plants.

In the beverage industry it is common for the initial stage to be a water-based rinse, this removes the remaining product from the system. Following this a caustic rinse is often undertaken, this removes materials that have adhered to the surfaces of the pipes and tanks. This is usually followed by a mix of water and acid rinses and then by a disinfection cycle and then by further water rinses.

There are many chemical and thermal variations that are used in the CIP process, with hazardous disinfection chemicals such as peracetic acid (commonly called PAA) and Bromoacetic acid being utilised.

Frequency of CIP Cycles to Maintain Beverage Hygiene

The frequency of CIP / DIP cycles depends on the plant operators methodology and the sensitivity of the products. 

In our experience, all operators undertake CIP before and after every change of product, many also undertake frequent programmes during production cycles – typically we see these range in frequency from 4-60 hour intervals. If the plant is dormant overnight it is also common to run a CIP cycle prior to shutdown and then to run another cycle prior to start up. 

 CIP / DIP cycles usually take between 30 and 90 minutes.

Using Anolyte in the CIP / DIP cycle Anolyte replaces the disinfection and acid stages of the CIP cycle. The benefits of this are that –
  • The cycle time can be reduced
  • The water use can be reduced 
  • The chemical costs can be reduced 
  • The chemical hazard is removed (Anolyte is non-hazardous) 
This results in significant time and cost savings.

Below are examples of a pipework CIP cycle that we have amended for a client showing the time, water and chemical savings.  It should also be noted that reduction of chemical usage has a positive impact on waste water quality and thus treatment costs.
Filler Cabinet CIP

The Aquadron undertakes filler cabinet CIP on a permanent and continuous basis.  This is undertaken during a running bottling process and ensures that the highest levels of hygiene are achieved during the filling process.  As a result of the the hygiene is improved and the need for process stops for disinfection are also removed.  This saves time and money.  As can be seen in the example below, continuous disinfection removed the need for 52 minute process breaks and reduced water use signficantly.
Cost Reduction in CIP
 
In addition to the significant time savings the chemical and energy costs of the CIP process can be significantly reduced. The table below shows cost comparison data from an Aquadron client site - 

Summary

Anolyte is an effective disinfectant that can be produced in a cost-effective and safe manner.  The use of Anolyte as produced by the Aquadron can improve CIP processes and in particular can have the following benefits - 
  • Filler cabinet hygiene can be improved,
  • Time savings can be achieved, 
  • Cost savings can be achieved, 
  • Water volumes can be reduced, 
  • Chemical loadings on waste water can be reduced, 
  • Energy use can be reduced, 
  • Chemical hazards can be reduced.
The ingredients used (food-grade pure common salt + conditioned water) for Innowatech Anolyte production correspond to the UK and European drinking water ordinances and the Biocide Directive.  Engineering, construction, installation and service of the Aquadron systems are also compliant to laws and guidelines for water treatment, disinfection etc in the UK and the European Union. 
Guaranteed Disinfection
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