Cleaning in Place (CIP)

What is Cleaning-in-Place (CIP)?

Cleaning-in-Place (CIP) is an advanced cleaning method used to sanitize the interior surfaces of tanks, pasteurisers, pipelines, and other process equipment—all without the need for disassembly. This automated cleaning process is widely used in industries such as food and beverage, pharmaceuticals, and dairy processing, ensuring hygiene, efficiency, and compliance with safety regulations.

Key Principles of an Effective CIP System

A well-designed CIP system operates based on four fundamental principles:

Temperature – The right heat level enhances cleaning effectiveness.
Chemical Concentration – Proper cleaning agents break down residues.
Mechanical Action – Fluid movement and pressure aid in removing contaminants.
Time – Sufficient exposure ensures thorough sanitation.

Step-by-Step CIP Cleaning Process

The CIP process involves multiple cleaning phases to ensure complete sanitation:

Initial Rinse: Equipment is flushed with hot water to remove leftover particles, flavours, and sugars.
Caustic Wash: Hot water (80°C) mixed with 1.5% Caustic Soda or 120°C pressurized steam circulates to break down contaminants.
Final Rinse: A final hot water rinse removes any remaining cleaning agents, leaving the equipment sanitized and ready for use.

Why Use CIP Systems?

Implementing a CIP system improves efficiency, reduces downtime, and enhances product safety. It is a cost-effective, eco-friendly, and automated solution for industries requiring stringent hygiene standards.

Why Use Ozone in CIP Cleaning?

Ozone (O₃) is a powerful, eco-friendly disinfectant that enhances the Cleaning-in-Place (CIP) process by eliminating biofilms, reducing chemical usage, and improving efficiency. It offers a safer, faster, and more cost-effective alternative to traditional cleaning methods.

Key Benefits of Ozone in CIP Systems

✅ Disinfects and Eliminates Biofilm – Ozone effectively removes stubborn biofilms, bacteria, and organic residues, ensuring superior hygiene.
✅ Reduces Water, Energy, and Chemical Use – Since ozone works with cold water, it replaces harsh chemicals and reduces overall resource consumption.
✅ Faster Cleaning Cycles – Ozone eliminates the need for additional rinse and disinfection steps, saving time and improving productivity.
✅ No Waste, No Residues – Ozone naturally decomposes into oxygen, leaving no harmful byproducts or affecting the final product quality.
✅ Cost-Effective & Low Risk – Lower energy consumption and reduced chemical use make ozone-based CIP more profitable while minimizing contamination risks.
✅ Improved Wastewater Quality – Ozone breaks down organic contaminants, reducing discharge levels and improving environmental impact.

How Ozone Works in CIP Cleaning

🔹 Cold Water Disinfection – Ozone eliminates the need for high-temperature rinses, cutting energy costs and cleaning times.

🔹 Superior Bacteria Removal – Unlike traditional disinfectants, ozone penetrates surfaces and destroys bacteria embedded in biofilms.

🔹 3000x More Effective Than Chlorine – Ozone reacts rapidly with organic matter, offering a disinfection power far stronger than chlorine.

🔹 Simple Application – By injecting ozone gas into water, it creates high-purity, microbe-free cleaning solutions.

🔹 Advanced Dissolution Methods – Various gas-liquid mixing techniques ensure efficient ozone distribution for maximum cleaning effectiveness.

Why Switch to Ozone for CIP?

Using ozone in CIP cleaning means better sanitation, lower costs, and an eco-friendly approach. It is a proven alternative that helps industries reduce downtime, improve efficiency, and maintain the highest hygiene standards.

Key Operating Parameters for Ozone-Based CIP Systems

For an effective and efficient ozone-based Cleaning-in-Place (CIP) system, maintaining the right operating parameters is crucial. The two most important factors are water flow rate and redox potential, which directly impact the biocidal efficiency of ozonized water.

1. Redox Potential: Ensuring Effective Disinfection.

The redox potential (ORP) must exceed 850 mV to ensure the biocidal properties of ozonized water. If ORP drops below this limit, water disinfection cannot be guaranteed, reducing its effectiveness against microbes and biofilms.

2. Water Flow Rate: Impact on Ozone Generation.

Water flow rate plays a critical role in determining ozone production from the generator. Based on our experience, a 1.0 mg/L ozone dose is easily achievable when the ozone generator is running at optimal conditions.

3. Ozone Concentration in Water

The concentration of dissolved ozone is a key factor, though it is not continuously measured. Maintaining proper ozone dissolution ensures maximum microbial elimination and optimized CIP performance.

Why These Parameters Matter

By carefully controlling redox potential, water flow rate, and ozone concentration, industries can enhance cleaning efficiency, reduce contamination risks, and minimize resource consumption.

Process Verification for Ozone-Based CIP Systems

Ensuring the effectiveness of an ozone-based Cleaning-in-Place (CIP) system requires regular monitoring and validation. Various measurement techniques and quality control procedures help maintain optimal ozone concentration, guaranteeing consistent disinfection performance.

1. Ozone Concentration Monitoring

✅ Scheduled ozone measurements are conducted to control ozone levels in water and verify process efficiency.

✅ The spectrophotometric method is used to accurately measure dissolved ozone concentration, ensuring reliable disinfection.

2. ORP Monitoring for Process Validation

✅ An Oxidation-Reduction Potential (ORP) indicator measures ORP directly from the ozonation tank, confirming the system is operating effectively.

✅ Maintaining a high ORP level (>850 mV) ensures that the biocidal properties of ozone remain active.

3. Equipment Maintenance & Performance Checks

✅ Our company provides periodic inspections of ozone generators, replacing spare parts and verifying operational efficiency.

✅ Regular maintenance ensures consistent ozone production and long-term reliability.

4. Microbial & Chemical Testing for Disinfection Efficiency

✅ Many of our customers schedule microbial and physicochemical analyses to validate ozone disinfection performance.

✅ Studies confirm that ozone is as effective—if not more—than traditional chemical disinfectants, with higher microorganism reduction rates in some cases.

5. Effective Biofilm Removal

✅ A proper ozone-based cleaning procedure must break down extracellular polymeric substances (EPS) in biofilms.

✅ This ensures that sanitising agents effectively reach bacterial cells, preventing microbial contamination.

Why Process Verification Matters

By implementing scheduled ozone monitoring, ORP tracking, routine maintenance, and microbial testing, industries can ensure optimal disinfection, regulatory compliance, and enhanced cleaning performance.

Ozone CIP Market Applications

Ozone-based Cleaning-in-Place (CIP) systems are widely used across various industries due to their high-efficiency disinfection, reduced chemical usage, and eco-friendly benefits.

Key market areas include:

✅ Winemaking – Ensures hygienic fermentation tanks, barrels, and pipelines, preventing microbial contamination without affecting wine quality.

✅ Beverage Industry – Used in bottling plants, juice production, and breweries to maintain sanitary processing conditions.

✅ Food Processing – Effective for sanitizing conveyors, mixers, and production surfaces, ensuring food safety compliance.

✅ Dairy Industry – Provides chemical-free cleaning of milk storage tanks, pasteurizers, and pipelines, enhancing product purity.

✅ High-Purity Water Applications – Used in pharmaceuticals and cosmetics to maintain ultra-pure water systems free from contaminants.Why Choose Ozone for CIP?Industries adopting ozone-based CIP benefit from:

✅ Superior disinfection without chemical residues

✅ Faster cleaning cycles and reduced downtime

✅ Lower water and energy consumption

✅ Compliance with strict hygiene regulations