Aspects of an intelligently
optimised CIP system
Dr. Jörg Zacharias, KRONES AG
Within the framework of the “Cleaning-in-Place of
Pipes and Tanks” seminar held by the EHEDG 1
and the FEI (Research Association of the German
Food Industry) Cooperation Forum 2016 2, this topic had
already been addressed by Dr. Jörg Zacharias. Back then, it
was shown how the fundamental task of a CIP system helps
to define what dependences a cleaning strategy is subject
to and how these influence the conception and design of
the CIP system. All this entails the necessity for a holistic approach
to cipping, as also discussed in 3. At the FutureClean
2018 4 and the 2019 Food Safety Forum 5, the topic was
presented in an expanded form to include adaptive smart
approaches. These aspects will be discussed below.
What precisely does CIP mean?
CIP stands for “Cleaning in Place”, and signifies that the
system(s) concerned (e.g. tank, mixer, flash pasteuriser, filler,
etc.) are cleaned individually or together in a recirculated
or straight-through process without major changes having
to be made to the kit concerned compared to the production
status. Cleaning solutions are for this purpose moved
along the surfaces involved by means of pumps, or sprayed
onto them through appropriately designed spray heads.
CIP systems form the basis for reproducible production processes.
They are a relevant constituent of the entire matrix.
Figure 1 shows a standard version as an example. Without
CIP, there would be no automation. Nonetheless, most CIP
processes are run with rigidly preprogrammed settings; an
adapted CIP optimisation is rarely performed.
Basically, of course, CIP systems can be regarded as
stand-alone, independent, autonomous tanks. But it is increasingly
evident that this is difficult in highly automated
Fig. 1: Standard CIP system with three tanks (KRONES
beverage plants, especially in 24/7 operation. Rather, the
market is evolving towards integrating CIP systems completely
into the production sequence, or even into the process
itself, so that soundly based, sustainable, affordable
and sequence-optimised production schedules become possible.
Here, however, errors in the planning stage often lead
to substantial effects on production – mostly in the form of
additional outlay, product losses and ultimately higher costs.
The watchword is accordingly: “Production begins at
the source and ends with successful cleaning”.
This necessitates as a precondition a harmonised hygiene
concept for the design involved, and a consistently
coherent CIP strategy, meeting the fundamental stipulation
of “The line has to become dependably clean!” – sustainably
• But how can this be accomplished?
• What are the boundary conditions and key data for CIP
• How can a philosophy for cleaning be delimited and demand