Washing stations with closed system CIP (Cleaning in Place) became an obligatory equipment element for foodstuff processing companies which complies with requirements of HACCP system. Responding to the expectations of our clients in 2004 there were installed washing stations – mechanical and fully automated, operating with Siemens or GE Fanuc controllers.
The basic functions of the cleaning station:
• Automatic preparation and control of cleaning solutions,
• Automatic dosing of concentrated cleaning agents,
• Controlling concentration of cleaning solutions by conductance measurement,
• Controlling the temperature of cleaning solutions,
• The possibility of programming work for specific cleaning circuits referring to the real cleaning time and the cleaning temperature,
• The possibility of chemical disinfection,
• Full and complete automation of cleaning process,
• Detecting deviations from cleaning processes set parameters,
• Pouring and regulating solutions in tanks of the cleaning station:
- maximum and minimum level sensors,
- electromagnetic valves on the tank’s water supply,
• Controlling concentration of working cleaning solutions:
- conductance measurement in the internal circuit,
• Controlling the temperature of cleaning solutions:
- temperature measurement in tanks of cleaning solutions,
- temperature regulation by the usage of a steam valve,
- temperature and concentration measurement during the process of cleaning solutions return,
• Controlling the division of returning solutions from cleaning circuits:
- conductance measurement of solutions returning to the cleaning station,
- separation of phases and stages on the basis of the preset cut-off points,
• Work programming of the cleaning station, depending on the character and size of the chosen cleaning circuits:
- duration of particular cleaning operations,
- cleaning temperature,
- the possibility of choosing a cleaning programme.
The system equipped with AUTO-CLEANING function, enabling internal cleaning of the CIP station tanks.
The CIP cleaning station consists of the following units:
• Cleaning alkaline solution vessel,
• Cleaning acidic solution vessel,
• Rinsing cold water vessel,
• Rinsing hot water vessel,
• Heating unit for alkaline cleaning agent,
• Heating unit for rinsing water,
• Measurement and regulation unit for alkaline cleaning solution,
• Measurement and regulation unit for acidic concentration of cleaning solution,
• Fittings, pumps and installation set,
• Automatic unit and electrical control.
The temperature sensor on the return pipe of cleaning agents enables the measurement of the real cleaning temperature, and thereby enables setting the effective and efficient cleaning time.
Measurement and regulation unit for cleaning agents concentration:
• Complete conductometer, located on the cleaning line return, for measurement and separation of the cleaning agents.
The unit enables:
• Automatic dosing of the cleaning and disinfection agent up to the desirable cleaning solution’s concentration by means of professional and designed for this application dosing pumps – 2 items,
• Maintaining the constant concentration of cleaning agent solution in lye (caustic alkali) and acid containers.
The set of fittings, pumps and installations includes
• The main cleaning CIP pump, the CIP return pump, automatic butterfly valves, flow sensors, pipe installations, inside the station.
The system of automatics, control and visualisation
The system of automatics and cleaning is created on the basis of a SIEMENS microprocessor controller.
In the stainless steel box, the controller and all the other elements of controlling are placed, together with power circuits and pneumatics. On the front of the box, there is an additional manual panel TOUCH MULTIPANEL produced by the SIEMENS company and with its help an operator of the cleaning station chooses particular cleaning programmes and observes the progress of cleaning cycles. On the panel, cleaning processes carried out by the CIP station are visible.
Valves
• Flap valves between the flanges , including control head and actuator; Steam fitting, control valves, plug valves; Condense – dehydrators, liquefiers, return valves, filters; Heating systems, shell and tube exchanger; Pumps; Membrane pumps; Control and measuring equipment.
Automation and control
• Controller SIEMENS; Touchscreen control panel; Contactors and motor protection; Inverter; Stainless steel cabinets; Level sensors; Temperature sensors; Pressure sensors; Flowmeter; Flow sensor; Safety transmitter; Inductive sensors; Repair switches; Valve terminal; Power rails; Cable trays; Electric cables; Remote access; Air preparation system.
The station is designed on the basis of one four-chamber tank. Each chamber has a volume of 10m3, a chamber for soda, acid, secondary water and clean water. The tank and the valve manifold will be made and connected to the control cabinet and tested at our factory. On the tank, will be connected all the valves and sensors (control and measurement apparatus AKPiA).
