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CIP Savings in the Dairy, Beverage, brewing Plant by using Additive to caustic

Updated: Jan 9, 2023

Typical CIP (clean in place) systems use two, three, or even four dedicated tanks that rinse or wash solutions. These tanks can range in size from 500 ltr up to, and even more than, 1500 ltr. Most CIP systems have a freshwater tank, an alkaline tank, an acid tank, and a reclaim tank, in addition to several pumps and a network of piping that supply and return wash solutions from the equipment being washed in place. They also have a heat supply and a programmer that controls the pumps, steam, valves, and chemicals' concentration.

Most CIP systems are set up to have a pre-rinse first, then an alkaline wash, then a freshwater rinse, then an acid wash, followed by a freshwater rinse, and then a sanitising step. "Additive to Caustic" cleaning products provide the following features, saving water, time, energy, and chemicals.

  1. Reducing Caustic consumption by 25-50%

  2. Reducing the rinse following the alkaline wash. "CIP Additive" makes easy caustic rinsing of wash solution faster than traditional cleaners.

  3. Eliminating the acid wash or increase in frequency-Lesser ACID CIP steps in a month.

  4. Better descaling and cleaning of PHE and Evaporator

The following is an example of savings generated by implementing a "Caustic Additive" cleaning program on a CIP system doing 22 CIPs per month that uses a 200,000 ltr (200m3) per CIP that has caustic-lye consumption of 1600 ltr/CIP. These are not theoretical numbers but, in fact, actual real-case representations of systems in the field. Ecocare has worked with CIP systems with "caustic additive" cleaning programs for three years. Initially, we were skeptical and had to perform against one of the leading suppliers of Indian dairy value-added manufacturer. Hence it was a challenge to come up with one of the best-formulated products to achieve the saving target set by the customer with exceptional cleaning capability while providing significant savings of water, time, energy, and chemicals.

Total savings:

  1. Water: 800 m3 (800,000 ltr)/month

  2. Time: 32 hours/month.

  3. Energy: Unproductive 32 hours/month from heating caustic and acid solutions, CIP pumps runnings, and Extra ETP running managing High TDS of CIP solution drained to ETP

  4. Chemical: 3.1million INR ($36K)/annum. Caustic saving calculator of CIP

It is essential to note that saving time may be the most important item in this group. Creating more time for an employee or a production shift can enormously impact productivity, which is called opportunity cost. For the employee, it opens up opportunities to focus on and accomplish other tasks. For the production shift, it may mean the addition of more production time.

"It is doing new things to bring the change," If you follow the instructions and parameters for using this "Additive" in CIP, it delivers excellent results. This program has been running at 4 dairies and delivering savings month on month.

You can calculate tangible savings by click the link of your plant.

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