Level and Flow Applications for Clean-In-Place Skid Systems

Clean-in-Place (CIP) is a method of cleaning the interior surfaces of pipes, vessels, process equipment, filters, and associated fittings without disassembly. Industries that rely heavily on CIP are those requiring the highest levels of hygiene, and include: dairy, beverage, brewing, processed foods, pharmaceutical & biotech, and cosmetics. Clean-in-place systems, like many process industry systems, can be fabricated as modular skids for greater efficiency and decreased site disruption. This post, part of a Magnetrol® occasional blog series on modular skid applications, will discuss level and flow control for clean-in-place skid systems.

Pharmaceutical CIP/SIP Skid

A clean-in-place skid cleans and sterilizes process systems to the highest hygienic standards. A Sterilization-in-Place (SIP) process (attained by steam, hot water, or chemical means) is typically included as is a chemical dosing system, tubular heat exchanger, chemical reclamation, and rinse water recovery system.

Water is pumped into rinse and detergent tanks, is dosed with detergent and chemicals, then heated and pumped to applications. Spent wash returns to the recovery tank for caustic reclamation. Typical CIP/SIP phases are: 1. Pre-rinse; 2. Alkaline wash; 3. Primary air-blow; 4. Rinse; 5. Acid wash; 6. 2nd air-blow; 7. WFI rinse; 8. Sterilization; and 9. Final air-blow.

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Level and Flow Applications

  1. Rinse Tank Water is pumped from the rinse tank in pre-rinse and subsequent rinse phases that follow the wash cycles. Level controls maintain water level in the rinse tank.
    Continuous Level: Eclipse® Model 706 Guided Wave Radar Transmitter
    Point Level: Echotel® Model 961/962 Ultrasonic Switch
  1. Detergent Tank The bulk cleaning liquid and water are pumped to the detergent tank before each cleaning cycle to make up a batch of detergent. The detergent is typically pumped through a plate heat exchanger for more effective cleaning.
    Continuous Level: ECLIPSE Model 706 Guided Wave Radar Transmitter
    Point Level: ECHOTEL Model 961/962 Ultrasonic Switch
  1. Recovery Tank A CIP caustic recovery system reclaims useable caustic solution from spent caustic streams. The spent CIP caustic solution is collected in a recovery tank and is processed through a membrane system in batch or continuous modes.
    Continuous Level: ECLIPSE Model 706 Guided Wave Radar Transmitter
    Point Level: ECHOTEL Model 961/962 Ultrasonic Switch
  1. Chemical Tanks The most common basic cleaners metered from storage tanks are potassium hydroxide and sodium hydroxide. A base wash is often followed by an acid wash of phosphoric acid, acetic acid, or citric acid.
    Continuous Level: ECLIPSE Model 706 Guided Wave Radar Transmitter
    Point Level: ECHOTEL Model 961/962 Ultrasonic Switch
  1. Air Flow Air blowing clears alkaline and acid solutions from the CIP lines and reduces rinsing time, and the amount of water required to clear the circuit of chemicals. Flow controls detect low-flow conditions and the presence or absence of air flow.
    Flow Alarm: Thermatel® Model TD1/TD2 Thermal Dispersion Switch for low-flow cutoff
    Continuous Gas Flow: THERMATEL Model TA2 Thermal Dispersion Mass Flow Meter

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