Validated and cost-effective cleaning

A validated cleaning process is a must for ensuring microbiological hygiene and avoiding cross-contamination. "CIP systems are the beating heart of every food & beverage plant," says Danny Smets, Business development Manager at Agidens. "But CIP processes are also responsible for nearly 30% of total plant utilities consumption. So there is a need from the market for a system that makes these crucial processes more transparent and efficient."

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OptiCIP, developed by Schneider Electric and integrated by Agidens in the Benelux, monitors and optimizes cleaning operations. Smets: "The OptiCIP software is applicable to any automation system and collects relevant data about the course of the cleaning process. After an audit of the existing CIP unit and any associated objects and after implementation and configuration of the software, we work with the customer to set up the most efficient cleaning per installation. In practice, the savings achieved in this way often turn out to be underestimated. We are therefore pleased to be able to integrate such software into existing or new processes at customers."

Golden CIP

An important feature of the software is the Golden CIP model. Smets: "For each CIP object, based on the results from the test period, we can set up an optimal CIP scenario per object to be cleaned, or Golden CIP. For each object, all parameters such as temperatures, cleaning times and chemical dosages per recipe step are set that lead to the most optimal cleaning quality and energy consumption. This Golden CIP is entered into the software as a reference. Each cleaning can then be compared with the Golden CIP via the software. The results are clearly displayed on a clear dashboard. Detailed reports displayed per object clearly show trends, anomalies, performance and product losses. If a discrepancy does occur, it is automatically indicated. The Golden CIP offers an automated, detailed and digital control method that gives the user assurance of cleaning quality. The entire quality control is also recorded and stored digitally, which is useful if something needs to be verified or traced afterwards."

Nothing but benefits

The advantages of OptiCIP are numerous: the process flow is immediately visible, and with the collected data it is possible to fine-tune the installation and set up the most optimal (cost-saving) cleaning. Johan Cools, EcoStruxure Plant leader at Schneider Electric, clarifies, "Operational costs such as water, energy, chemical consumption and time can be significantly reduced, as can cleaning time, product losses and environmental impact. Research shows that CIP processes account for as much as 30% of total energy consumption at food & beverage companies. With OptiCIP, we can significantly reduce this consumption. Downtime is also reduced, so production can be resumed faster. In most cases, this leads to a spectacular ROI. Cases of less than two years are far from exceptional. OptiCIP also benefits food safety because it identifies cleaning anomalies and is compliant with safety and quality regulations. In addition, the software is completely platform-independent."

CIP: from audit to realization

Optimizing CIP and everything that comes with it has become one of the specializations within Agidens in recent years. Smets explains: "We not only build new CIP installations, we also analyze existing CIP systems and the corresponding objects to be cleaned. With OptiCIP we complete our existing services to the customer. We take care of the CIP Audit, possible mechanical and automation adjustments, the implementation of the OptiCIP software, training of the customer's personnel, analysis of the results, fine-tuning and after-service. In short, the total picture for an efficient and insightful CIP process!