From data to results: optimising CIP processes and reducing costs
Clean-in-place (CIP) systems are essential for maintaining hygiene and efficiency in the food and beverage industry. However, CIP processes often face challenges such as excessive resource consumption, downtime and lack of insight into optimisation. A monitoring system such as IN-SITE CIP can revolutionise cleaning cycles, ensuring improved efficiency, cost savings and sustainability.
Monitoring a CIP system is critical to ensure effective and consistent cleaning, minimising the risk of contamination and ensuring product quality and safety. Proper control enables optimisation of resources such as water, energy and chemicals, reducing operating costs and minimising the impact on the planet. In addition, continuous monitoring helps detect errors, prevent downtime and extend equipment life by avoiding blockages, leaks or sensor malfunctions. It is also critical for meeting hygiene and regulatory standards, providing detailed records for audits and inspections, and ultimately improving the safety, efficiency and reliability of cleaning processes.
A robust CIP monitoring system provides detailed insight into the cleaning process, enabling data-driven decision making. Key benefits include cost reduction, increased productivity, improved sustainability by reducing waste and consequently CO2 emissions, improved product quality and safety, and better resource allocation that supports proactive maintenance and minimises disruption.
After the cleaning process, it is vital for the industry to interpret the results accurately to ensure optimum performance and compliance with hygiene standards. This is where reliable technical support becomes essential. A dedicated team with expertise in CIP systems and cleaning processes plays a key role in analysing data, identifying potential inefficiencies and providing recommendations for process optimisation. Ongoing guidance from experienced professionals helps the customer to maximise the effectiveness of their CIP system, ensuring thorough cleaning while minimising resource consumption. In addition, expert monitoring provides a better understanding of the overall health of the CIP system, enabling predictive maintenance and preventing unexpected failures, ultimately improving efficiency, safety and long-term equipment performance.
IN-SITE CIP can support you optimise your CIP
IN-SITE CIP consists of an advanced, non-intrusive remote monitoring software designed to improve the efficiency and reliability of CIP cleaning processes. Seamlessly integrating with existing PLC systems, it collects, analyses and interprets real-time data to provide valuable information on CIP performance. As mentioned above, with the included service and support, this solution enables industries to optimise cleaning cycles, reduce resource consumption and improve overall operational efficiency without having to change existing infrastructure. The software works in four key steps to ensure a streamlined, data-driven approach to monitoring and managing cleaning in place.
- Data gathering: The system records CIP activity 24/7 without the need for additional hardware, logging what, when and how cleaning is performed.
- Data processing: It generates reports covering:
- Quality verification
- Cost analysis
- Environmental impact
- Operational efficiency
These insights are independent of SCADA systems, providing an unbiased view of CIP processes.
- Optimisation and reporting: IN-SITE CIP specialists analyse data and provide actionable recommendations. Power BI dashboards help users identify inefficiencies and trends, enabling:
- Comparative analysis (before and after optimisation)
- Action plans for improvement
- Training for operational teams
- Validation and continuous improvement: Once improvements have been implemented, IN-SITE CIP validates their effectiveness through a specialized software and a professional support. Real-time alerts alert users to variances, ensuring continuous improvement.
Proven value and impact
Many companies have experienced the benefits of IN-SITE CIP. Wyke Farms Ltd, a leading UK cheese producer, reported significant energy, water and chemical savings following implementation. Their Environmental Co-ordinator, Nigel Pritchard, said:
“IN-SITE CIP provides unparalleled visibility into our CIP cycles, which is essential for effective management. Without this insight, unnecessary energy, chemical and water consumption would continue. Thanks to IN-SITE CIP, we have optimised our processes, resulting in significant cost savings and sustainability improvements”.
A case study revealed significant improvements, highlighting a saving of 9.000 m³ of water per year and a reduction in chemical consumption costs of 54.000 €. In addition, the study showed a reduction of 92.000 € in water-related costs and an increase of 374 additional production hours per year, demonstrating the significant benefits of optimising the cleaning process.
Implementing IN-SITE CIP is a strategic investment for food and beverage manufacturers aiming to improve efficiency, reduce costs, and enhance environmental responsibility. By using real-time data and automation, companies can optimise resource usage, minimise waste, and maintain high hygiene standards while improving their overall operations.
IN-SITE CIP enables businesses to transition from reactive a proactive management of their cleaning processes. This shift helps prevent failures, enhances process safety, and ensures long-term operational excellence. With the support of a team of experts, this advanced solution boosts cleaning efficiency, reduces resource consumption, and extends the lifespan of equipment. For companies looking to optimise their CIP processes, IN-SITE CIP is the key to achieving greater efficiency, significant cost savings, and long-term success.
Luis Miguel Luengo
CIP application specialist at Cristeyns
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