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Powerful and flexible

Fully automatic plug and CIP modules
Powerful and flexible

The basis of high quality production is not only the manufacturing process itself but also the associated cleaning processes. Cleaning should ideally be fully automatic and conserve resources. With the newly developed WECIP concept for the cleaning units, the solution has been developed in a plug and CIP module. This CIP module can be quickly and easily integrated in processes, and cleans not only separator installations but also tanks and piping systems reproducibly and economically.

Hildegard Schnittker-Lips, Jörg Spanhoff

The WECIP concept from Westfalia Separator Engineering has generated a product line consisting of several different CIP modules: PharmaCIP for the pharmaceutical and chemical industries, BioCIP for biotechnical applications, DairyCIP for milk processing operations and BevCIP for brewery and beverage technology. The design of the each CIP concept is in accordance with the requirements and standards of the respective application. In the case of PharmaCIP, for example, GMP-compliant documentation can be delivered on request.
Autonomous cleaning modules
The cleaning units based on the WECIP concept are operated as autonomous modules. Each module incorporates all neces-sary components and is installed ready for connection on a frame.
Each module also has an independent control system. Alternatively, it can be incorporated in a master process control system. The actual program sequence depends on the apparatus to be cleaned and on the necessary cleaning cycles. The required parameters can be easily adapted to local conditions in the pre-set programs. The cleaning units work according to the principle of non-reusable cleaning media.
Cleaning tasks
The cleaning units of the WECIP generation are suitable for cleaning both closed piping systems and tanks and apparatus. When cleaning closed piping systems, the surface quality and the nature of the product play a significant role. Physical and chemical forces are responsible for dislodging the dirt residues. They are influenced by the flow velocity and the temperature. To clean a pipeline, a medium flow velocity of 2 m/s is recommended in order to achieve turbulent flow.
The cleaning tasks for tanks and apparatus are wide-ranging. Cleaning is to a large extent carried out using fittings such as spray balls and spray nozzles. Depending on the task at hand, sections of the equipment, complex geometric configurations or complete surfaces can be cleaned selectively. Apparatus and tanks can also be partially or completely flooded in order to flush out larger residual quantities or deposits.
The cleaning task must therefore always be considered on an individual basis and the cleaning components rated accordingly to suit the conditions. The required cleaning capacity, e.g. of a rotating spray nozzle, determines the necessary pressure and throughput parameters which must be made available by the CIP unit.
Cleaning sequence
To obtain an optimum cleaning result, suitable program steps and cleaning media must be selected. The first step is normally pre-flushing with water in order to remove coarse dirt particles. In the second step, an alkaline solution is prepared in the CIP module and adjusted to the required temperature. After completing the preparation, the program step is released and cleaning of the installation can begin. The third step is post-flushing with water after the actual cleaning time has elapsed.
Depending on the cleaning requirements, steps two and three can be repeated using alkaline solutions or cleaning agents.
Process sequence and monitoring
Conveying the media at the correct velocity and to heating them up is not the only task of a cleaning unit. Automatic switching of the paths during the cleaning steps and measuring, controlling and regulating the operating parameters are likewise indispensable requirements with respect to reproducibility and validation.
The cleaning agents are fed in by means of the installed metering pumps. A conductivity meter monitors and regulates the media concentration in the various cleaning circuits. Acid and caustic are drawn from commercially available drums and dosed as a function of their conductivity. The cleaning media are heated up indirectly via a heat exchanger in a bypass system. The temperature of the cleaning medium can be kept constant due to continuous checking and reheating.
The throughput necessary for constant cleaning performance can be achieved by a fixed rating of the CIP feed pump with a fixed operating point. If different process conditions are required in terms of flow rate and pressure, the process parameters can be adjusted by combining volume or pressure monitoring with a frequency-controlled pump. Operation and process control and monitoring of the cleaning parameters are realised by a PLC. Process and motor control are integrated in the control cabinet located on the cleaning unit. The solution with separate cleaning programs is equipped with an autonomous control unit. This control variant additionally allows a Profibus connection. WECIP can be connected to an existing cleaning unit by means of a control module with Profibus data exchange.
Process integration
The function-tested WECIP modules are completely assembled and wired. Only the supply media – water, compressed air and saturated steam – are required for integration in the process. Like the process connections, these interfaces are prepared for rapid assembly. Power is supplied via cables with cable connectors.
The unit is also available in a mobile version for lower capacities. To achieve maximum flexibility for this kind of application, the process can be connected by means of hoses.
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